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Transcript

User and maintenance manual
for generating sets
R230U
33504078701NE_0_1
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine
WARNING
The engine from this product contains
chemicals known to the State of California to
cause cancer, birth defects or other
reproductive harm
The state of California requires the above two warnings.
1. Preface........................................................................................................................................................................... 3
1.1.
General recommendations ................................................................................................................................ 3
1.2.
Pictograms and their meanings ......................................................................................................................... 4
1.3.
Instructions and safety regulations .................................................................................................................... 8
1.3.1 General advice .................................................................................................................................................. 8
1.3.2 Risks related to exhaust gases and fuels ......................................................................................................... 9
1.3.3 Risks related to toxic products ........................................................................................................................ 10
1.3.4 Risk of fire, burns and explosion..................................................................................................................... 10
1.3.5 Risks related to electrical networks ................................................................................................................ 11
1.3.6 Dangers presented by electric currents (first aid) ........................................................................................... 11
1.3.7 Risks related to moving the set....................................................................................................................... 11
1.4.
Identifying sets ................................................................................................................................................. 12
2. General description ...................................................................................................................................................... 14
2.1.
Description ....................................................................................................................................................... 14
2.2.
Technical specifications ................................................................................................................................... 17
2.3.
Fuel and consumables ..................................................................................................................................... 19
2.3.1 Specifications .................................................................................................................................................. 19
2.3.1.1.
Oil grades ............................................................................................................................................. 19
2.3.1.2.
Specifications of coolants .................................................................................................................... 20
3. Installation .................................................................................................................................................................... 21
3.1.
Unloading ......................................................................................................................................................... 21
3.1.1 Safety during unloading .................................................................................................................................. 21
3.1.2 Instructions for unloading................................................................................................................................ 21
3.1.2.1.
Slings ................................................................................................................................................... 21
3.1.2.2.
Fork lift truck ........................................................................................................................................ 22
3.2.
Fluid retention .................................................................................................................................................. 22
3.3.
Choice of location ............................................................................................................................................ 24
3.4.
Electricity .......................................................................................................................................................... 25
3.5.
Special arrangements ...................................................................................................................................... 27
4. Trailer ........................................................................................................................................................................... 27
4.1.
Trailer linkage .................................................................................................................................................. 27
4.2.
Check before towing ........................................................................................................................................ 27
4.3.
Operation ......................................................................................................................................................... 28
4.4.
Unhitching the trailer ........................................................................................................................................ 28
4.5.
Implementation for installation ......................................................................................................................... 29
4.6.
Break transmission adjustment........................................................................................................................ 29
4.7.
Faults and repairs ............................................................................................................................................ 31
4.8.
Electrical connection diagram .......................................................................................................................... 32
4.9.
Complete wheels technical information ........................................................................................................... 32
5. Preparation before operating the set ........................................................................................................................... 33
5.1.
Installation checks............................................................................................................................................ 33
5.2.
Checks after starting the generating set .......................................................................................................... 33
1/209
6. Using the generator set................................................................................................................................................33
6.1.
Pre-Start Inspection .........................................................................................................................................33
6.2.
Generator set with NEXYS control panel .........................................................................................................36
6.2.1 Control panel presentation ..............................................................................................................................36
6.2.1.1.
Introduction to pictograms ....................................................................................................................37
6.2.2 Manual starting ...............................................................................................................................................38
6.2.3 Switching off ....................................................................................................................................................39
6.2.4 Alarms and faults ............................................................................................................................................39
6.2.5 Faults and alarms - Details .............................................................................................................................40
6.3.
Generator set with TELYS control panel .........................................................................................................43
6.3.1 Control panel presentation ..............................................................................................................................43
6.3.1.1.
View of the front panel .........................................................................................................................43
6.3.1.2.
Description of the screen .....................................................................................................................45
6.3.1.3.
Description of the pictograms in zone 1 ...............................................................................................46
6.3.1.4.
Description of the pictograms in zone 2 ...............................................................................................47
6.3.1.5.
Description of the pictograms in zone 3 ...............................................................................................48
6.3.1.6.
Display of messages in zone 4 ............................................................................................................51
6.3.2 Starting ............................................................................................................................................................55
6.3.3 Switching off ....................................................................................................................................................56
6.3.4 Alarms and faults ............................................................................................................................................57
6.3.4.1.
Viewing alarms and faults ....................................................................................................................57
6.3.4.2.
Activation of an alarm or fault ..............................................................................................................58
6.3.4.3.
Activation of an alarm and a fault.........................................................................................................59
6.3.4.4.
Engine fault codes display ...................................................................................................................60
6.3.4.5.
Horn reset ............................................................................................................................................61
7. Maintenance schedule .................................................................................................................................................62
7.1.
Reminder of use ...............................................................................................................................................62
7.2.
Engine ..............................................................................................................................................................62
7.3.
Alternator..........................................................................................................................................................62
8. Battery ..........................................................................................................................................................................63
8.1.
Storage and transport ......................................................................................................................................63
8.2.
Battery setting into service ...............................................................................................................................64
8.3.
Check ...............................................................................................................................................................64
8.4.
Load preconization ...........................................................................................................................................65
8.5.
Faults and remedies ........................................................................................................................................66
9. Appendix ......................................................................................................................................................................67
9.1.
Appendix A – Engine user and maintenance manual ......................................................................................67
9.2.
Appendix B - Alternator user and maintenance manual ................................................................................133
9.3.
Appendix C - Common spare parts................................................................................................................193
9.4.
Appendix D - List of John Deere - Volvo and Perkins fault codes .................................................................195
2/209
1. Preface
1.1.
General recommendations
Thank you for choosing an electrical generating set from our company.
This manual has been designed to help you operate and maintain your electrical generating set correctly.
The information contained in this manual is taken from technical data available at the time of print. In line with our policy of
continually improving the quality of our products, this information may be amended without warning.
Read the safety instructions attentively in order to prevent any accidents, faults or damage. These instructions must always be
followed.
You are likely to encounter several warning symbols in this manual.
This symbol indicates an immediate danger to human health and life in case of exposure. Failure to follow
the corresponding advice entails serious consequences for human health and life in case of exposure.
Danger
This symbol draws attention to the potential risks to human health and life in case of exposure. Failure to
follow the corresponding advice entails serious consequences for human health and life in case of exposure.
Warning
This symbol indicates a dangerous situation if the warning is not heeded.
Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other
object in case of exposure.
Important
In order to obtain optimum efficiency and the longest possible life for the electrical generating sets, maintenance operations must be
carried out according to the periods indicated in the attached preventative maintenance tables. If the electrical generating set is
used under dusty or unfavourable conditions, some of these periods will be shorter.
Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training. Dealers have this
qualification, and can answer all of your questions. They can also supply you with spare parts and other services.
The left and right sides can be seen from the back of the electrical generating set (the radiator is at the front).
Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts
thereby reducing the out of action period to a minimum.
For any replacement of parts, contact your nearest dealer for our company who will have the necessary equipment and can offer
properly trained and informed staff to carry out maintenance, parts replacement and even total reconditioning of generating sets.
Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in
implementation and maintenance.
Important
Some user and maintenance manuals for the engines fitted to generating sets cover control units and
include the start-up and shutdown procedures for the engines.
As the generating sets are fitted with control units that are specific to the generating sets, only the
information that appears in the documentation for the generating sets' control units should be taken into
consideration.
In addition, according to the manufacturing criteria of the generating sets, some engines may be fitted with
specific electrical wiring different to that described in the engine documentation.
3/209
1.2.
Pictograms and their meanings
Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential
dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of
identification by the operator.
Replace any notice that is missing or illegible.
Caution: danger
Publications delivered
with the generating set
must be referred to
Caution: risk of explosion
Caution: risk of
electric shock
Protective
clothing
must be worn
Naked
flames
unprotected
prohibited.
No smoking
Caution:
materials
toxic
Eyes and ears must be
protected
Entry prohibited to nonauthorised persons
Caution:
pressurised fluids
Periodic maintenance
must be carried out
Jet washing prohibited
Caution:
high
temperature, risk
of burns
Battery level must be
checked
Earth
Caution: rotating
or moving parts
(risk of getting
caught in the
machinery)
Lifting point must be
used
Caution:
product
Fork pockets for
lifting
Retention
high
tank
and
lights
corrosive
level
Important: refer to the documentation accompanying the generating set.
Important: emission of toxic exhaust gases. Do not use in a confined or badly
ventilated area.
Figure 1.1 : Pictograms and their meanings
4/209
WARNING: DANGER
This symbol warns of a safety hazard. The presence of this symbol indicates a risk
of injury.
Observe the safety instructions and precautions for use.
Important:
Carefully read the instructions supplied with the generating set before using or
servicing the equipment.
WARNING: DANGER
Risk of electrocution
Do not touch the cables or connections when the generating set is in
operation.
Switch off the generating set for maintenance operations.
DANGER
Use diesel fuel only.
The fuel is highly flammable, handle with care. Do not smoke near the
generating set or expose it to a naked flame or sparks.
Shut down the generating set engine before filling the fuel tank. Fill with fuel
outside.
To prevent fire risks, clean the generating set regularly. Wipe away any dirt
and traces of grease or fuel.
WARNING: DANGER
The exhaust gases from the engine are toxic and can affect health or even
cause death.
Use the generating set outdoors only, in well ventilated areas, or fit an exhaust
extension to discharge the exhaust gases outside.
Figure 1.2 : Pictograms and their meanings
5/209
WARNING: DANGER
Hot coolant can cause serious burns.
Switch off the engine. Do not remove the filler cap until it is completely cold.
Do not open the radiator when it is hot.
DANGER
Rotating parts can cause serious injury.
Do not operate the generating set with the doors open.
Do not remove the enclosures.
Shut down the generating set before any maintenance or servicing
operation.
DANGER
Avoid any contact with the exhaust pipes, turbochargers and silencers.
Keep flammable materials away from hot parts.
Wait for the machine to cool down completely before touching it.
WARNING: DANGER
The gas from the battery electrolyte is explosive. Keep the batteries away
from any flames.
The battery electrolyte (sulphuric acid) is toxic. Risk of poisoning.
Figure 1.2 (continued) : Pictograms and their meanings
6/209
WARNING: DANGER
A poor earth connection can lead to serious injuries or death.
Always connect the earth terminal of the generating set to an external earth
terminal.
WARNING
Voltage selector
This function should be used by qualified persons only.
WARNING
Adjust the output voltage correctly before connecting a load.
WARNING
The voltage selector must not be used when the generating set is operating.
Figure 1.2 (continued) : Pictograms and their meanings
7/209
1.3.
Instructions and safety regulations
THESE SAFETY GUIDELINES ARE IMPORTANT
If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give
you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national
regulations that apply in accordance with your own jurisdiction.
KEEP THIS MANUAL
This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set
or batteries.
1.3.1 General advice
Use
The operating and safety instructions must be made known to operating personnel. They will be regularly updated.
Read and understand the manuals provided with the generating set, pump unit or lighting column properly. The manufacturer's
instructions must remain at the disposal of technicians, if possible in situ.
The facility must be operated under the direct or indirect supervision of a person appointed by the operator, who is familiar with
the operation of the facility, and the dangers and drawbacks of the products used or stored in the facility.
Do not wear loose clothing, or get close to machines in operation. Note that the fans are not clearly visible when the engine is
running.
Warn personnel present to keep their distance during operation.
Do not run the generating set, pump unit or lighting column without refitting the protective covers and closing all the access
doors.
Never let a child touch the generating set, pump unit or lighting column, even when shut down.
Avoid operating the generating set, pump unit or lighting tower in the presence of animals (disturbance, scares, etc.).
Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site. When
chocking the trailer on a slope; ensure that there is nobody in the path of the trailer.
Never start the engine without an air filter or exhaust.
Engine with turbocharger: never start the engine without fitting the air filter. The compressor wheel rotating inside the
turbocharger may cause serious bodily injury. Foreign objects in the inlet pipe may cause mechanical damage.
Engine with air preheating (starting components): never use a starting spray or any other similar starter assistance product.
Upon contact with the starting component, an explosion may occur in the inlet tube, causing bodily injury.
Do not touch the lighting column lights when they are switched on.
Maintenance
Follow the maintenance table and its instructions.
Always use tools in good condition which are suited to the work to be done. Ensure you have understood the instructions before
beginning any operation.
Goggles should be worn when carrying out maintenance operations and watches, bracelets etc. should be removed.
Fit only original parts.
Disconnect the battery and the pneumatic starter (if fitted) before undertaking any repairs, to prevent the engine from starting
accidentally. Fit a panel over the controls to prevent any attempt to start.
Only use the correct crankshaft turning techniques for turning the crankshaft manually. Do not try to turn the crankshaft by
pulling it or levering the fan. This method may cause serious bodily or material damage, or damage the vanes of the fan,
reducing the service life of the fan.
Clean off any trace of oil, fuel or coolant using a clean cloth.
Do not use a soapy solution containing either chlorine or ammonia, as these two chemicals prevent bubble formation.
Never use petrol or other inflammable substances to clean the parts. Use only approved cleaning solvents.
Do not use a high pressure cleaner for cleaning the engine and equipment. The radiator, hoses, electrical components, etc. may
be damaged.
Avoid accidental contact with parts at high temperatures (exhaust manifold, exhaust).
Before any maintenance operation on a lighting column light, cut the electrical power supply and wait for the bulbs to cool down.
Consumables
Observe regulations in force concerning use of fuel before using your generating set, pump unit or lighting tower.
Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.
8/209
Environment
The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be
maintained in a good state of cleanliness.
The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants
and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products
and dust.
The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the
operating requirements.
Facilities must be operated under the constant supervision of a qualified person, who must regularly check that the safety
devices are operating correctly and ensure that the combustion devices have the correct fuel supply.
Apart from the combustion devices, it is prohibited to use fire in any form. This restriction must be clearly displayed.
Spreading of waste water, sludge and waste is prohibited.
The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the
combustion device manufacturer.
The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber.
Burning of waste in the open air is prohibited.
Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause serious damage.
Risk of blood contamination.
Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).
Except by special agreement, once closed, the gas supply main unit must only be re-opened by the gas distributor. However,
the user may access it under certain conditions. Check these for each site.
1.3.2 Risks related to exhaust gases and fuels
Danger
The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air
breathed are too high.
Always use generating sets, pump units or lighting towers in a well-ventilated place where gases cannot
accumulate.
In case of indoor use:
Be sure to evacuate exhaust gases outdoors.
Provide appropriate ventilation so that personnel present are not affected.
Observe the local regulations in force for generating sets, pump units or lighting towers, as well as local regulations for use of
fuel (petrol, diesel fuel and gas) before using your generating set, pump unit or lighting tower.
Fuel filling should be carried out when the engine is off (except for generating sets with an automatic filling system).
Engine exhaust gases are toxic: do not run the generating set, pump unit or lighting column in unventilated premises. If installed
in a ventilated room, additional requirements for fire and explosion protection must be observed.
A leaking burnt gas exhaust may increase the sound level of the generating set, pump unit or lighting column. To check on its
efficiency, regularly examine the burnt gas exhaust.
Pipes must be replaced as soon as their condition demands it.
9/209
1.3.3 Risks related to toxic products
Warning
Glycol is a toxic product and dangerous if absorbed.
The corrosion inhibitor contains alkali.
Avoid all contact with the skin and eyes. Read the
Do not swallow it.
instructions on the packaging.
This substance should not come into contact with the
eyes. In the event of contact with the eyes, rinse
immediately with plenty of water for at least 15
minutes.
Avoid prolonged or repeated contact with the skin. In
the event of contact with the skin, wash thoroughly
with water and soap. CONSULT A DOCTOR
IMMEDIATELY. KEEP THE PRODUCT OUT OF
THE REACH OF CHILDREN.
The anti-rust product is toxic and dangerous if
absorbed. Avoid all contact with the skin and eyes.
Read the instructions on the packaging.
Caution: fuels and oils are dangerous to inhale. Ensure proper ventilation, and use a protective mask.
Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground.
The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately with running water
and/or a 10% diluted boric acid solution.
Wear protective eyewear and strong base resistant gloves for handling the electrolyte.
1.3.4 Risk of fire, burns and explosion
The engine should not be operated in environments containing explosive products. As not all of the
electrical and mechanical components are shielded, there is a risk of sparks forming.
Danger
Make sure not to create sparks or flames, and not to smoke near the batteries, as the electrolyte gases are highly flammable
(especially if the battery is charging). Their acid also poses a risk to the skin, and in particular to the eyes.
Never cover the generating set, pump unit or lighting tower with any material during operation or just after shutdown (wait for the
engine to cool).
Do not touch hot parts such as the exhaust pipe, or put combustible materials on it.
Keep all flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when the set is running.
Proper ventilation is required for your generating set, pump unit or lighting column to work properly. Without this ventilation, the
engine would very quickly rise to an excessively high temperature, causing accidents or damage to the equipment and to
surrounding property.
Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns.
Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.
Watch out for the possible presence of pressure when disconnecting a device from a pressurised system. Do not try to find
pressure leaks by hand. Oil at high pressure can cause bodily damage.
Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask.
Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out any
procedures. Never start or run the engine with the oil filler cap off (oil may splash out).
Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust.
Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot.
A generating set can only operate when stationary, and cannot be installed on a vehicle or other mobile equipment, without a
prior study taking into account the various specific features of using the generating set.
10/209
1.3.5 Risks related to electrical networks
The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of
the countries in question.
The earth connection must be installed in accordance with the standards in force in each country in question, and with the
neutral system sold.
Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check
that these values match the supply use.
Never accidentally touch stripped cables or loose connections.
Never handle a generating set with wet hands or feet.
Maintain electrical wires and connections in good condition. Using equipment in poor condition can lead to electrocution and
damage to equipment.
Always disconnect the power to the equipment or facility (generating set voltage, battery voltage and network voltage) before
any operation.
The electrical connections must be made in accordance with current standards and regulations in the country of use.
Do not use faulty, poorly insulated or provisionally connected wires.
Never reverse the positive and negative terminals on batteries when connecting them. This could cause severe damage to the
electrical equipment. Follow the wiring diagram supplied by the manufacturer.
The generating set should not be connected to any other power sources, such as the mains supply network. In specific cases
where there is to be a connection to existing electrical networks, this must only be installed by a qualified electrician, who should
take the operating differences of the equipment into account, according to whether the mains supply network or generating set
is being used.
Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be by
components with identical nominal values and specifications.
If the protective plates (blanking covers) need to be removed to route cables, the protector (blanking cover) must be refitted
when the operations are finished.
Due to high mechanical stresses, use only strong flexible wiring with rubber sheathing, compliant with IEC 245-4, or equivalent
wiring.
1.3.6 Dangers presented by electric currents (first aid)
First aid
In the event of an electric shock, shut off the power immediately and activate the
emergency stop on the generating set or lighting column. If the voltage has not yet
been cut off, move the victim out of contact with the live conductor as quickly as
possible. Avoid direct contact both with the live conductor and the victim's body. Use
a dry plank of wood, dry clothes or other non-conductive materials to move the victim
away. The live wire may be cut with an axe. Take great care to avoid the electric arc
that will be generated by this.
Begin emergency procedures
Resuscitation
If breathing has stopped, begin artificial respiration at once in the same place the accident took place unless the victim or operator's
life could be endangered by this.
In the event of cardiac arrest, carry out cardiac massage.
1.3.7 Risks related to moving the set
To unload the generating sets, pump units or lighting columns from their transport support brackets under optimum safety and
efficiency conditions, you must ensure that the following points are observed:
The lifting machinery or equipment is suited to the work required, in good condition and with sufficient lifting capacity.
The slings are positioned in the rings provided for this operation, the forklift arms are resting fully underneath all of the base
frame cross-beams, or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire
generating set (according to models).
For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set, pump unit
or lighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains and
cables must be parallel with each other, and as perpendicular as possible with the upper edge of the generating set, pump unit
or lighting column.
If other equipment fitted on the generating set, pump unit or lighting column alters its centre of gravity, special lifting devices
may be necessary to maintain correct balance and completely safe working conditions.
The ground must be able to withstand the load of the generating set, pump unit or lighting column and its lifting machinery
without stress (otherwise, put down beams of sufficient strength in a stable configuration).
Position the generating set, pump unit or lighting column as close as possible to its place of use or transport, in a clear space
with free access.
Never perform work on a generating set, pump unit or lighting tower just hanging from a lifting device.
11/209
1.4.
Identifying sets
Generating sets and their components are identified by means of identification plates.
The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents
contained in this manual.
Examples of identification plates
Generating set
Engines
Figure 1.3 : Examples of identification plates
12/209
Alternator
Cabinet
Figure 1.4 : Examples of identification plates
13/209
2. General description
2.1.
Description
Overview
3
2
1
2
3
Circuit breakers
Control unit
External emergency stop
4
5
6
Battery charge alternator
Protective grilles
Filling with fuel
External fuel supply combined tap
(optional)
1
5
4
7
7
6
Figure 2.1 : General description of the generating set
14/209
8
10
9
11
8
9
Circuit breaker
Starter battery
10
11
Connection termination box
Chassis
Figure 2.1 (continued) : General description of the generating set
15/209
Sockets ( voltage 208/120V )
16/209
2.2.
Technical specifications
RENTAL POWER / R230U
Range / Generating set type
Weights and Dimensions
Dimensions with standard tank
Dimensions l x w x h :
3508 mm x 1200 mm x 1830 mm
Weight :
2540 kg dry weight 2890 kg in operating configuration
Hood :
M226C
Noise level (measurement uncertainty) :
82 dB @ 1 m (0.70)
72 dB @ 7 m (0.70)
Dimensions with high autonomy tank
Dimensions l x w x h :
3560 mm x 1200 mm x 2182 mm
Weight :
2960 kg dry weight 3790 kg in operating configuration
Hood :
M226C-DW
Noise level (measurement uncertainty) :
82 dB @ 1 m (0.70)
72 dB @ 7 m (0.70)
Output
Voltage
Hz
Phase
Load factor
Current (A)
480/277V
380/220V
220/127V
208/120V
60
60
60
60
3
3
3
3
0,8
0,8
0,8
0,8
302
381
659
669
Emergency power 1
kW / kVA
200.8 / 251
304,8 / 381
527,2 / 659
532,2 / 669
Prime power 2
kW / kVA
182,5 / 228,2
182,6 / 228,2
182,6 / 228,2
175,3 / 219,1
(1) ESP: Stand-by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528-1, no
overload available under these service conditions.
(2) PRP: Main output available continuously under variable load for an unlimited time period per year as per ISO 8528-1, an
overload of 10% one hour every 12 hours is available, as per ISO3046-1.
Engine data
Manufacturer / model
Type
Cylinder configuration
Cubic capacity
Rotation speed
Max emergency/prime power at nominal speed
Adjustment type
VOLVO TAD733GE
Turbo
6xL
7.15 L
1800 Rpm
225 / 202 kW
Electronical
Fuel consumption
110 % (emergency power)
100 % main power
75 % main power
50 % main power
54.0 L/h
47.6 L/h
35.2 L/h
23.8 L/h
17/209
Fuel
Fuel type
Standard fuel tank
High autonomy fuel tank
Diesel
340 L
868 L
Lubrication
Oil capacity with filter
Min. Oil pressure
Nominal oil pressure
Oil consumption (100 % load)
Oil sump capacity
Type of lubricant
34 L
2 bar
4 bar
0,09 L/h
31 L
Genlub
Cooling
Engine capacity with radiator
Max coolant temperature
Fan power
Refrigerant type
Thermostat
35,8 L
105°C
3,4 kW
Gencool
87-102°C
Alternator data
● Compliant with NEMA MG21 standards, UTE NF C51.111,
VDE 0530, BS 4999, IEC 34.1, CSA
Type
Number of phases
Power factor (cos Phi)
Number of poles
Excitation type
Voltage regulator
Short-circuit current
Number of bearings
Coupling
● The alternator is protected against short circuits
● Vacuum impregnation, epoxy winding, IP23 protection
rating
LEROY SOMER LSA462M5
3
0.8
4
AREP
R450
3 IN
1
Direct
Control unit(s)
NEXYS
Standard specifications:
Frequency meter, Voltmeter, Ammeter
Alarms and faults:
Oil pressure, Coolant temperature, Fail to start, Overspeed,
Alternator min/max, Fuel level low, Emergency shutdown
Engine parameters:
Working hours counter, Engine speed, Battery voltage,
Fuel Level, Air Preheating
TELYS
Standard specifications:
Voltmeter, Ammeter, Frequency meter
Alarms and faults:
Oil pressure, Water temperature, Start failure, Overspeed,
Alternator min/max, Battery voltage min/max, Emergency
stop
Engine parameters:
Timer, Oil pressure, Water temperature, Fuel level, Engine
speed, Battery voltage
18/209
2.3.
Fuel and consumables
All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual.
In addition, we recommend the consumables to be used in the "specifications" section.
2.3.1 Specifications
2.3.1.1.
Oil grades
Engine
Oil
Make
Type
John Deere
All
MITSUBISHI
Volvo
All
All
Make
John Deere
GenPARTS
GenPARTS
GenPARTS
Type
John Deere PLUS-50
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W-40
Top-of-the-range lubricant recommended for diesel engines: for generating sets used under severe conditions.
USES:
Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems
(e.g. HEUI, injector-pumps).
All types of use: can cope with the most demanding applications.
Depolluted engines: complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel,
especially ecological diesel with low sulphur content.
PERFORMANCE:
ACEA E3
API CH-4
Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition.
ADVANTAGES:
Less frequent oil services: this product has been put to the test during thousands of hours of use on worksites under
varying conditions, demonstrating its high quality.
Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2
and EURO 3 engines.
SPECIFICATIONS:
SAE Grade
15W-40
Density at 15°C
Cinematic viscosity at 40 °C
Cinematic viscosity at 100 °C
Viscosity index
Dynamic viscosity at -15 °C
Pour point
Flash point
Sulphated ash content
(Values given as examples only)
0.883
mm2/s (cSt)
mm2/s (cSt)
105
14.1
140
3000
- 30
220
1.4
mPa.s(cP)
°C
°C
% weight
19/209
2.3.1.2.
Specifications of coolants
Engine
Coolants
Make
John Deere
Type
All
MITSUBISHI
All
Volvo
All
Make
GenPARTS
Mitsubishi
GenPARTS
GenPARTS
Type
GENCOOL PC -26°C
LLC
GENCOOL PC -26°C
GENCOOL PC -26°C
GenCOOL PC -26
High-protection coolant, approved by manufacturers.
GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority
of European manufacturers.
It is made from antifreeze and G 48 inhibitors.
It protects up to -26°C.
It is free from nitrates, amines and phosphates.
It is a clear, fluorescent orange liquid.
REFERENCES/APPROVALS (for the antifreeze):
HEAVY GOODS VEHICLE
LIGHTER VEHICLES
Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERAL Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE
MOTORS
Conforms with VOLVO, IVECO,
STAYR TRUCK specifications
VAN
HOOL
and Conforms with VOLVO, OPEL, SEAT and SKODA specifications
Conforms with the NF R 15.601 standard
REINFORCED ANTI-CORROSION FEATURES:
Protects against high-temperature corrosion by oxidisation of ethylene (cylinder head protection).
Protects against high-temperature cavitation (top of cylinder and coolant pump protection).
Non-corrosive for seals and hoses.
Improves the efficiency and longevity of the cooling system.
GenCOOL PC -26 is especially recommended for engines fitted with aluminium or light alloy radiators.
HIGH TEMPERATURE SUITABILITY:
Provides good conditions for thermal exchange.
Perfect stability at high temperatures.
GenCOOL PC -26 is specially adapted for engines with high power densities.
LONG LASTING PROTECTION:
High alkaline reserve/stability and longevity of corrosion inhibitors.
Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids).
Ensures maximum heat transfer without the build up of deposits in the cooling system.
GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use.
PACKAGING/STORAGE:
GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings.
It can be stored for 2 years in its original container and packaging.
Avoid zinc coated containers.
20/209
RECOMMENDATIONS FOR USE:
Compatible with the original fluid.
It is recommended that the cooling system is completely drained when replacing the fluid.
UNITS
SPECIFIED VALUES
TRIAL
METHODS
kg/m3
1,059 +/- 3
R 15-602-1
pH
pH
7.5 to 8.5
NF T 78-103
Alkalinity reserve
ml
>=10
NF T 78-101
Boiling point
°C
105 +/- 2
R 15-602-4
°C
-26 +/- 2
NF T 78-102
SPECIFICATIONS
Density at 20°C
Freezing point:
Glassware
corrosion
(test with antifreeze)
:
mg/test piece
R 15-602-7
- Copper
+/- 2.6
- Weld
+/- 0.5
- Brass
+/- 2.3
- Steel
+/- 1.6
- Cast iron
+/- 0.8
- Cast aluminium
Corrosion on warm
(test with antifreeze)
+/- 1.0
plate
mg/(cm²week)
+/- 0.17
R 15-602-8
3. Installation
3.1.
Unloading
3.1.1 Safety during unloading
To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions, you need to
ensure that the following points are observed:
- Lifting machinery or equipment appropriate to the work required.
- Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members.
- Ground able to take the load of the set and the lifting machinery without stress (otherwise lay down beams of sufficient strength
and stability).
- Set put down as close as possible to its point of use or transportation, in a clear area with free access.
Example of equipment to be used:
crane, slings, cross bar, safety catch, shackles.
Fork lift truck.
3.1.2 Instructions for unloading
3.1.2.1.
Slings
Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully.
Check that the slings are correctly attached and the equipment is solid.
Lift the generating set carefully.
Direct and stabilise the set towards the chosen position.
Carefully set down the equipment while continuing to position it.
Release the slings, then detach and remove the lifting rings.
21/209
3.1.2.2.
Fork lift truck
Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position
the forklift arms in these pockets), making sure that only its cross-members are resting on the arms.
Lift the equipment, handling it gently.
Set down the generating set in its unloading position.
Figure 3.1 : Transporting a generating set using a forklift truck
3.2.
Fluid retention
Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in a
retention container if the generating set is fitted with this option.
The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.
Three different fittings are available.
Figure 3.2 : Fluid retention container integrated into the tank chassis.
22/209
Figure 3.3 : Offset fluid retention container underneath the generating set chassis.
Figure 3.4 : Offset fluid retention container integrated into the chassis and tank.
Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container.
In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or
condensation). If necessary, drain the containers either via the drain port or by using the drain pump (for containers fitted with this
pump).
Note : Never allow these fluids to drain onto the ground; ensure they are collected in a designated container.
23/209
3.3.
Choice of location
It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the
electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of
these gases and the noises emitted should be taken into account.
The choice of its position will be based on carefully considered compromise!
Examples of problems that may be encountered:
Incorrect exhaust and ventilation
Ground too uneven or soft.
Set incorrectly positioned
Fuel filling impossible
Reduced access
Opening cover doors impossible
Figure 3.5 : Examples of problems that may be encountered
24/209
3.4.
Electricity
a) Connections - general information
As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards
in the relevant country, based on international standard IEC 60364-6-61.
They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the
relevant country.
b) Power cables
These can be unipolar or multipolar according to the power of the generating set.
Power cables should preferably be installed in ducts or on a cable tray for this purpose.
The cable cross-section and number of cables should be determined according to the cable type and the current standards to be
observed in the country of installation. The choice of conductors must comply with international standard
IEC 30364-5-52.
Three phase - Calculation hypothesis
Fitting method = wiring in cable runs or non perforated trays.
Permissible voltage drop = 5%
Multiconductors or single conductor joined when precision 4X…(1)
Cable type PVC 70°C (e.g. H07RNF).
Ambient temperature = 30°C.
Cable sizes
Circuit breaker
calibre
(A)
10
16
20
25
32
40
50
63
80
100
125
160
250
400
630
(1)
(1)
(1)
(1)
(1)
0 - 50m
mm²/AWG
1.5 / 14
2.5 / 12
2.5 / 12
4 / 10
6/9
10 / 7
10 / 7
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X95) / 4/0
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
51 - 100m
mm²/AWG
2.5 / 12
4 / 10
4 / 10
6/9
6/9
10 / 7
10 / 7
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X150) / 2350MCM
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
101 - 150m
mm²/AWG
4 / 10
6/9
6/9
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X95) / 4/0
4X(1X150) / 2350MCM
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
Single phase - Calculation hypothesis
Fitting method = wiring in cable runs or non perforated trays.
Permissible voltage drop = 5%
Multiconductors.
Cable type PVC 70°C (e.g. H07RNF).
Ambient temperature = 30°C.
Circuit breaker
rating (A)
10
16
20
25
32
40
50
63
80
100
125
Cable sizes
0 - 50m
51 - 100m
101 - 150m
mm²/AWG
4 / 10
6/9
10 / 7
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
35 / 2
50 / 0
mm²/AWG
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
35 / 2
50 / 0
50 / 0
70 / 2/0
95 / 4/0
mm²/AWG
10 / 7
16 / 5
25 / 3
25 / 3
35 / 2
50 / 0
50 / 0
70 / 2/0
95 / 4/0
95 / 4/0
120 / 2250MCM
c) Battery cables
Install the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected directly from the
battery terminals to the starter motor terminals.
The primary instruction to follow is to ensure that the polarities between the battery and starter motor match. Never reverse the
positive and negative battery terminals when connecting them. This could cause severe damage to the electrical equipment.
The minimum cross-section of the cables will be 70 mm2. It varies according to the power of the starter motor but also the distance
between the batteries and the set (voltage drops on the line).
25/209
d) Safety guidelines
References: NFC 15-100:2002 (France) - IEC: 60364-5-54
In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector
"factory" set to trigger instantly, with a sensitivity of 30 mA.
Important
Any modification to this setting could endanger personnel. Any modification would render the user liable, and
must only be performed by qualified and authorised personnel.
When the generating set is disconnected from a facility after use, the master differential protector must be
returned to its "factory" settings, and this must be checked by trained personnel.
For effective protection against electric shocks, the generating set needs to be earthed. To do this, use a copper wire, with a
minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected to the generating set earth
socket and a galvanised steel earthing rod embedded vertically into the ground.
The earthing rod resistance value should comply with the values shown in the table below.
Note: use the highest differential setting from the installation as a guideline.
The resistance value is calculated in the following way:
R = Ul
I Δn
Maximum resistance value of the earth socket R (Ω) according to the differential unit operational
current (operation time should not be longer than 1 second).
I Δn
differential
Earth R
(Ω)
Ul: 50 V
500
500
167
100
50
17
10
5
≤ 30 mA
100 mA
300 mA
500 mA
1A
3A
5A
10A
Earth R
(Ω)
Ul: 25 V
> 500
250
83
50
25
8
5
2.5
The Ul value: 25 V is required for work site installations, and livestock buildings, etc.
For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below:
Nature of ground
Thick arable land,
moist compact ballast
Lean arable land,
Gravel, coarse ballast
Bare stony soils, dry sand,
impermeable rock
Length of
rod in
metres
1
1
3.6
To obtain an equivalent length, you can use several earthing rods
connected in parallel and set apart by at least their length.
Example: 4 interconnected 1 metre rods separated by 1 metre.
Note: For the United States (National Electrical Code reference NFPA-70).
The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most)
connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically.
This earthing rod embedded fully in the ground must have a minimum length of 2.5 m.
26/209
3.5.
Special arrangements
Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring.
The company does not accept any responsibility regarding damage caused by these occurrences.
However, lightning conductors can be installed, on the understanding that this does not give total protection.
4. Trailer
4.1.
Trailer linkage
Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.
Warning
Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious
accidents.
Also check:
- no incipient fractures or excessive wear on the hitching system.
- locking system is operating properly.
To hitch the trailer, proceed as follows:
Lock the wheels to stop the trailer from moving
Lift up the rear trailer supports and lock them
Release the parking brake
Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook
Hitch the trailer, remove the locks on each side of the wheels then lift up the front wheel fully using its handle
Connect the electrical circuit of the trailer to that of the tow vehicle
Hook the handbrake safety wire onto the hook on the tow vehicle.
CORRECT
CORRECT
Tow vehicle
Tow vehicle
Trailer
Trailer
INCORRECT
INCORRECT
Tow vehicle
Tow vehicle
Trailer
Trailer
Figure 4.1 : Coupling a trailer
4.2.
Check before towing
Before towing, check the following:
Tightness of the generating set enclosure bolts.
Wheel tightness.
Hitching hook locked.
Tyre pressure.
Signalling lights working, for "on-road" trailers.
Enclosure doors closed.
Parking brake released, for "on-road" trailers.
Guide wheels (jockey wheels) and stands lifted (if fitted).
Towbar arm locking levers tightened and pinned (if fitted with an adjustable towbar).
Brake test, for "on-road" trailers.
Safety cable fitted, for "on-road" trailers.
27/209
4.3.
Operation
"On-site" trailer
These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h.
So it is absolutely prohibited to exceed this speed.
Nor are these trailers fitted with signalling lights. On-road use is prohibited.
"On-road" trailer
The driving speed must be suited to the condition of the road and the handling of the trailer.
Driving at high speed causes heating of the tyres; so it is important to stop from time to time, and check them. Excessive heating
may cause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake.
Particular attention must be paid to the tightness of the wheels on new vehicles.
In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. It
is therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted.
Nonetheless the tightness must be checked whenever you are about to tow the trailer.
Warning
Lights/signalling (only for "on-road" trailers)
Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.
Front reflective devices (white)
Red rear lights
+ direction indicators
+ stop lights
Rear reflective devices
(red triangle)
Side reflective devices (orange)
Figure 4.2: Example of French signalling
4.4.
Unhitching the trailer
This operation should be carried out on horizontal, flat, stable ground.
Lock the wheels
Lower the front wheel
Disconnect the road signals wire
Refit the hitch using the wheel to release the hook ring from the tow vehicle,
Release the tow vehicle
Engage the handbrake.
28/209
4.5.
Implementation for installation
Operations to be carried out:
Ensure that the ground is strong enough for the assembly not to sink into it.
Unhitch the trailer.
Immobilise the trailer by placing chocks under the wheels.
Fully engage the parking brake (if fitted).
Using the front wheel, position the generating set as close to horizontal as possible.
Lower the stands (if fitted), and lock them.
4.6.
Break transmission adjustment
- The handbrake is used only as a parking brake.
- Setting is carried out starting with the brakes moving to the brake control.
Important
After fitting the wheels on the axle, turn the wheels in the FORWARD direction (on all RA 2 type brakes, check that the
adjustment screw 8 reaches the “FORWARD” stop on the brake backing plate).
Adjust the brake setting using screw 8, with the cables not connected to the cross bar(s). The shoes should rub the drum
slightly.
Connect the brake cables to the cross bars(s) and tighten the nuts and lock nuts, leaving the end of the threaded end
protruding by around 10 mm (Fig. 4.4).
IMPORTANT: Wherever possible, cables must cross over to achieve the highest possible gain curve (Fig. 4.5).
Check that the parking lever 1 is in the ‘REST” position and that the compensating spring 4 is completely free on its rod
(unscrew the nuts 5 fully).
Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position.
Fit the transmission and adjust the assembly using the tensioner 6 until a gap (J1) of 1 mm max is obtained between the
linkage 9 and slide 2.
Adjust the compensating spring 4 at one end pressing it against the anchorage plate, and at the other end leaving a 2 mm gap
(J2) max between the spring and nuts 5.
Tighten all the lock nuts.
Checking the setting (trailer on axle stands):
Pull the parking lever 2 notches - the wheels cannot turn in a FORWARD direction.
The wheels can turn in REVERSE (adjustment screw 8 switches to the REAR position).
Pull the parking lever fully.
The wheels will not turn either in FORWARD or REVERSE and the cross bar(s) must remain parallel with the axle body.
Check the transmission setting after 180 miles (300 km) (running in period) and if necessary adjust the gap (J1) using the
tensioner.
Parking
The lever must be fully pulled up, so that the compensating spring is fully compressed.
Every 900 miles (1500 km), check the braking settings and distribution on all the wheels.
Important
The brake controls are designed to draw trailers behind flexible suspension touring vehicles. If used behind an HGV, be
sure to provide the fitted ball joint with a shock absorber to prevent premature wear.
During any manoeuvres with the trailer coupled, do not turn more than 90° or force reverse.
The specifications of our brake controls are indicated on a manufacturer's plate, and the items on this should be supplied
to us when requesting replacement parts, in particular for the shock absorber, of a special type, approved by the Service
des Mines to correspond to European standards (it is advisable to have a spare shock absorber to enable instant repairs).
29/209
Figure 4.3 : Braking transmission
Figure 4.4 : Cross bar fitting
Figure 4.5 : Tandem bearing fitting
30/209
4.7.
Faults and repairs
Fault observed
Erratic braking of trailer
Braking too weak
Drum temperature abnormally high
Jerky braking
Origin
- Faulty shock absorber
- Jaws worn
- Jaws not run in
- Incorrect linkage setting
- Significant friction on the slide
- Slide corrosion
- Coupling height does not match that of
the towing vehicle
- Incorrect linkage setting
- Incorrect brake setting
- High levels of dust in the drums
- Jaws, springs, drums damaged
- Brake cables or link rod damaged
- Incorrect linkage setting
- Interfering parts on the slide
- Corroded slide
- Damage to slide guide rings
- Faulty shock absorber
- Cross-bar(s) not balanced
- Different brake setting on the two sides
Trailer tending to swerve upon braking
- Cables damaged or incorrectly fitted
- Poor load distribution
- Damage to slide or to guide rings
- Slide corrosion
When starting the trailer holds back the
towing vehicle
- Tie rod damaged
- Linkage damaged or incorrectly set
Play in the coupling head
Parking braking too weak
- Brake on
- Head worn (see wear indicator)
- Ball joint worn
- Compensating spring incorrectly set
- Braking system incorrectly set
- Notched sector damaged
- Lever ratchet worn
- Cable ruptured
31/209
Solutions
Replace the shock absorber
Replace the jaws
Fault will disappear only after running in
Adjust the setting
Grease the sliding parts
Remove the corrosion and grease
Adjust the height so that the two parts
are in the same horizontal plane
Adjust the settings
Adjust the settings
Remove the dust
Replace the damaged parts
Replace the damaged parts
Adjust the settings
Remove, clean and grease
Remove the corrosion and grease
Replace the rings (and possibly the
slide) and grease
Replace the shock absorber
Adjust the cross-bar(s)
Adjust the brake settings
Replace the damaged parts
Refit the cables
Check the load distribution
Replace the faulty parts and grease
Remove the corrosion and grease
Replace the tie rod and adjust the
settings
Replace the damaged parts and adjust
the settings
Loosen the brake
Replace the head
Replace the ball joint
Adjust the setting
Adjust the setting
Replace the sector and adjust the setting
Replace the lever and adjust the setting
Replace the cable and adjust the setting
4.8.
Electrical connection diagram
Figure 4.6 : Electrical connection diagram
4.9.
Complete wheels technical information
COMPLETE
WHEELS
TYRES
Dimensions
Indices
Diameter (mm)
Cross section
(mm)
135 R 13
145 R 13
155 R 13
145/70 R 13
155/70 R 13
185/70 R 13
165 R 14 C
70 T
75 T
79 T
71 T
75 T
86 T
98 N
550
566
578
534
548
594
622
134
145
150
150
147
185
172
Radius under
load
(mm)
265
272
277
259
263
285
284
155/70 R12
100 N
525
155
244
185 R 14 C
102 P
650
188
316
106 P
666
98 N
450
(2)
Wheel with 5 holes
198
190
32
-
195 R 14 C
195/50 x 10
(1)
Wheel with 4 holes
32/209
Load
(Kg)
Pressure
(bar)
335
387
437
345
387
530
650
(1)
650
(2)
800
(1)
675
(2)
850
950
750
2.4
2.4
2.4
2.5
2.5
2.5
3.8
6.25
4.5
4.5
6.0
5. Preparation before operating the set
The inspections referred to in this section enable the electrical generator set to operate.
Specific skills are required to carry out these operations.
They must only be entrusted to personnel with the necessary skills.
Failure to follow these instructions in any way could result in malfunction or very serious accidents.
Danger
5.1.
Installation checks
Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.) are observed.
Carry out the level checks (oil, water, diesel fuel, battery).
Check the generating set earth connection is earthed.
Check that the electrical connections are in order.
5.2.
Checks after starting the generating set
Carry out the mechanical checks (oil pressure, water temperature, absence of noise etc.).
Carry out the electrical checks (voltage and frequency).
Carry out the safety checks (emergency stop, oil pressure, water temperature etc.).
6. Using the generator set
6.1.
Pre-Start Inspection
Engine and engine compartment, general check
Visually check the engine and engine compartment before starting the engine and after stopping the engine.
Check:
There are no oil, fuel or coolant leaks.
The screws are tightened.
The condition of the belts (wear, tension).
Fuel, oil and grease deposits on the engine or in the engine compartment are always a fire hazard and must
be removed as soon as they are noticed.
Warning
If there are any oil, fuel or coolant leaks, locate the origin of the fault and repair it immediately before starting
the engine.
Important
Never use a high pressure cleaner for cleaning the engine and equipment.
Important
Oil level, check and top up
The oil level must be checked every day before the first start-up.
Check that it is between the MAX and MIN marks on the oil dipstick.
If necessary, top up the oil through the filler opening, on the left-hand side of the
engine.
With the engine switched off, wait a few minutes for the oil to drain into the oil sump
before checking the level.
Never fill oil past the maximum level.
Only use oil of the recommended grade.
Important
33/209
Coolant level, check
Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be
ejected.
Warning
The system must be filled up with liquid which has identical proportions to that already contained in the
cooling system
Important
Check the coolant level daily, before starting the equipment.
Top up if necessary.
The coolant level should be approximately 5 cm below the edge of the filler cap seal.
Checking the air filter clogging indicator
Special air filters must be used for extremely dusty conditions.
Important
The air filters must be replaced if the indicator remains in the red zone after the
engine is stopped.
After the filters have been replaced, press the button to reinitialise the indicator.
34/209
Checking the fuel pre-filter
The fuel is highly flammable and its vapours are combustible.
The fuel pre-filter must only be bled when the engine is stopped and cold.
Danger
Check that there is no water or sediment at the bottom of the pre-filter.
If necessary, drain the pre-filter using the following procedure:
Undo the drain plug (A) at the bottom of the pre-filter by two or three turns.
Collect the water and/or sediment in a suitable container.
When fuel starts to flow out, tighten the drain plug.
Check that there are no leaks.
If necessary, reprime the fuel circuit.
A
External check and cleaning of the radiator
Do not use a high pressure cleaner to clean the radiator.
Take care not to damage the radiator fins.
Important
Remove the guards to access the radiator.
Clean with water and a gentle detergent. Clean using a soft brush.
Refit the guards.
35/209
6.2.
Generator set with NEXYS control panel
6.2.1 Control panel presentation
9
7
1
9
10
2
3
6
9
5
8
9
4
Figure 6.1 : View of the front side
Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage
equipment
Key switch for starting up/shutting down the module and RESET function
Electronic card protection fuse
Screen-scroll button, press successively to access the various screens which are available
STOP button, press to switch off the generating set
START button, press to switch on the generating set
Normal operation LEDs and alarm and fault warning LEDs
Slot reserved for panel fascia options
Mounting bolt.
LCD for displaying alarms and faults, operating states, electrical and mechanical quantities
36/209
1
2
3
4
5
Figure 6.2 : Description of the LEDs
A lit LED indicates:
Module being supplied (green, lights up and remains lit)
Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)
Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to
generate (green, lights up and remains lit)
General alarm (orange, flashing)
General fault (red, flashing).
6.2.1.1.
Introduction to pictograms
The pictograms are as follows:
Operating temperature
Fuel
Symbols for electric and
mechanical sizes
Overspeed
Battery
Non-starting fault
Starting on external command
Preheating
Air intake
Delay
Oil pressure
Figure 6.3: View of pictograms
The "fuel level" pictogram is used to display the fault, the alarm and the fuel level.
The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value
The "overspeed" and "non-starting fault" pictograms are used to display the fault.
The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.
37/209
6.2.2 Manual starting
Check that the generating set circuit breaker has triggered.
Danger
Connect the generating set battery.
Turn the key switch to the ON position (without forcing it)
All of the LEDs light up for 2 seconds, to confirm that they are operating correctly.
If the LEDs do not light up, check the protection fuse and replace it if necessary.
All the items on the screen are displayed for 2 seconds.
Only the "ON" LED remains lit to indicate that the module is powered up.
The following screen appears.
The first line displays the motor speed in RPM.
The second line displays the battery voltage in
volts (V).
Check the battery voltage (min. 12 V)
Press (once briefly) the green "START" button.
If the motor is equipped with an air preheating system, there is a 10-second delay before the motor starts
(preheating activation period).
The following screen appears
The third line displays the air preheating time
remaining (with pictograms representing a
resistor and an hourglass).
If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts
up (start of a cycle comprising 3 attempts to start up the engine).
The following screen appears.
The number of successive and automatic starting attempts is limited to 3.
Warning
flashes as soon as the START button is pressed and continues to flash until the frequency
Note: the LED
stabilises if a "measurements" card has not been inserted and until the frequency and voltage stabilise if a
"measurements" card has been inserted.
Following stabilisation, the LED light comes on
continuously.
38/209
6.2.3 Switching off
Trigger the circuit breaker located at the base of the centre console.
Let the motor run under no load for 1 to 2 minutes to allow it to cool.
Press the "STOP" button to stop the generating set.
Switch off the MICS Nexys module by switching the key to "OFF" (without forcing it).
6.2.4 Alarms and faults
The appearance of a fault or an alarm causes the following
screen to be displayed (one or more pictograms or a fault code
along with the SOS message are displayed).
The user can access the following screens by pressing the key
The fault or alarm screen will disappear once the fault or alarm has been removed.
Only one fault is displayed on this screen (the fault which caused the generating set to stop).
If one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset (press
"Reset" as many times as the number of faults present).
Note : an alarm can appear at the same time as a fault.
39/209
6.2.5 Faults and alarms - Details
List of faults which will cause the generating set to stop and generate a pictogram
Associated pictogram
Oil pressure fault: Indicates that the oil pressure is incorrect
Associated pictogram
Engine temperature fault:
temperature is too high.
Indicates
that
the
engine
Associated pictogram
Non-starting fault: Indicates that there have been three
consecutive unsuccessful starting attempts.
Associated pictogram
Overspeed fault: Indicates an excessive generating set running
speed.
Associated pictogram
Low fuel level fault: Indicates the need to top up the fuel.
40/209
List of faults which will cause the generating set to stop and generate a fault code
Associated message
Low coolant level fault: indicates that the level of coolant is low
in the radiator (linked to a two second time delay).
Or
Overload or short-circuit fault (optional): with the circuit breaker
SD contact closing (overload or short-circuit), the generating
set switches off immediately also causing the main circuit
breaker to be triggered.
Additional fault linked to message opposite: is displayed in the
following two cases:
Differential fault (1)
insulation fault (2)
(1) Differential fault (optional): with a differential fault causing
the activation of the differential relay, the generating set
stops immediately also causing the main circuit breaker to
be tripped.
(2) Insulation fault (optional): with an insulation fault causing
the activation of the control unit performing insulation, the
generating set stops immediately.
Associated message
Associated message
Underspeed fault: indicates an incorrect rotation speed (below
1000 rpm).
Associated message
Emergency stop or external emergency stop fault
Associated message
"STOP" fault activated if the "STOP" button is pressed whilst
the "AUT" LED is flashing to indicate that the generating set is
operating in automatic mode.
41/209
List of alarms associated with a pictogram
Associated pictogram
Low fuel level alarm: Indicates the need to fill up with fuel.
Associated pictogram
"Alternator charging fault" alarm indicates a problem affecting
the alternator charging rate.
42/209
6.3.
Generator set with TELYS control panel
6.3.1 Control panel presentation
6.3.1.1.
View of the front panel
9
1
13
6
7
9
5
12
2
3
9
8
10
11
4
9
Figure 6.4 : View of the front panel
1
2
3
4
5
6
7
8
9
10
11
12
13
Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or
damage equipment.
Key switch for switching the module on/off.
Electronic board protection fuse.
Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel.
STOP button, press to switch off the generating set.
START button, press to switch on the generating set.
Power ON LEDs and alarm/fault warning LEDs.
Location of USB ports.
Mounting bolt.
LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities.
ESC button: for returning to the previous selection and for default RESET function.
MENU button for accessing the menus.
Lighting for the emergency stop button.
43/209
1
2
3
Figure 6.5 : Description of the LEDs
A lit LED indicates:
1
Alarm activated (flashing yellow).
2
Fault found (flashing red).
3
Module on (green, on continuously).
1
2
3
Figure 6.6 : Close-up of USB ports
1
2
3
USB key connection (HOST): file transfer between USB key and TELYS and vice versa.
Connection for microcomputer (DEVICE):
file transfer between PC and TELYS and vice versa,
main module power supply.
Protective cover.
44/209
6.3.1.2.
Description of the screen
The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.
SERIAL No.: 08030010000
SOFTWARE: 5.3.5
NOMINAL VOLTAGE: 400V
FREQUENCY: 50Hz
NOMINAL KW: 320kW
EARTH SYSTEM: TNS
Figure 6.7 : Description of the screen (example)
Zone 1 : in this zone, the status of the generating set is displayed
Zone 2 : in this zone, pictograms relating to dimensions measured are displayed, as well as Alarm and Fault pictograms
Zone 3 : in this zone, the measured values corresponding to the measured dimensions are displayed with the corresponding
units of measurement
Zone 4 : in this zone, messages relating to the control of the generating set and the menus are displayed.
Note : The information displayed on measurements, alarms and faults as well as messages and menus relating to control of the
generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.
45/209
6.3.1.3.
Description of the pictograms in zone 1
Pictograms in zone 1
Pictograms
Activation conditions
TELYS in manual mode (MANU)
Display
Fixed
"MANU" Mode
Flashing
For 5 seconds when switching from AUTO
mode to MANU mode
Fixed
TELYS in automatic mode (AUTO)
Flashing
For 5 seconds when switching from MANU
mode to AUTO mode
Flashing
Generating set in start-up phase
Fixed
Generating set started
Fixed
Generating
frequency)
"AUTO" Mode
Flashing
(appearance
of
movement from left to right)
Fixed
constant
set
The generating
installation
stabilised
set
is
The installation is supplied
Not used
Not used
46/209
(voltage
and
powering
the
6.3.1.4.
Description of the pictograms in zone 2
Alarm and fault pictograms in zone 2
All the pictograms in this zone are activated when TELYS is initialised.
Data displayed
Fuel level indicator
Alarm / Fault
high fuel level
Alarm / Fault
low fuel level
Alarm
Low level
fault
High
level fault
alarm
Coolant level / temperature indicator
Alarm
High
temperature
fault
Battery
Min battery
voltage
(flashing)
No preheating
fault
alarm
Battery charge
indicator
(flashing bars)
Max
battery
voltage (flashing)
Oil pressure
Alarm / Fault
Oil pressure / temperature indicator
High or low oil
level
Alarm /
Fault
Emergency stop
High or low oil
temperature
Alarm / Fault
Emergency stop fault
Overload or short circuit
Tripping of circuit breaker following an overload
or short circuit
Engine speed
Underspeed fault
Overspeed fault
47/209
Non-starting fault
6.3.1.5.
Description of the pictograms in zone 3
Pictograms in zone 3
All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples.
Generating set stopped
Screen no.
Pictograms
Data displayed
Fuel Level Indicator
Indication of Temperature of High Temperature coolant
(HT) (units according to settings menu)
P1
Indication of Battery Voltage
Indication of Oil Temperature (units according to
settings menu)
Generating set start-up or generating set started or generating set switching off in progress
Screen no.
Pictograms
Data displayed
Engine Speed Indication
Indication of Temperature of High Temperature coolant
(units according to settings menu)
P2
Indication of Oil Pressure (units according to settings)
Indication of Oil Temperature (units according to
settings menu)
48/209
Generating set started
Screen no.
Pictograms
Data displayed
Fuel Level Indicator
P3
Default
screen in
operation
Alternator composite Voltage Indicator
Total Active Power Indicator
Alternator Frequency Indicator
U12 Alternator composite Voltage Indicator
U23 Alternator composite Voltage Indicator
P4
U31 Alternator composite Voltage Indicator
Alternator Frequency Indicator
V1 Alternator single Voltage Indicator
V2 Alternator single Voltage Indicator
P5
V3 Alternator single Voltage Indicator
Alternator Frequency Indicator
U12 Alternator composite Voltage Indicator
V2 Alternator single Voltage Indicator
P6
V1 Alternator single Voltage Indicator
Alternator Frequency Indicator
V1 Alternator single Voltage Indicator
P7
Single phase Alternator current indicator
Alternator Frequency Indicator
49/209
Screen no.
Pictograms
Data displayed
Single phase Alternator current indicator
Two phase Alternator current indicator
P8
Three phase Alternator current indicator
Neutral Alternator current indicator
Total Active Power Indicator
Total Reactive Power Indicator
P9
Total Effective Power Indicator
Total Power Factor Indicator (lagging or leading)
Fuel Level Indicator
P10
Indication of Battery Voltage
Indication of Battery Amps
Screen order of appearance according to network type with the generating set on.
Type of network
Order of appearance
1
2
3
4
5
6
7
3P+N
P3
P4
P5
P8
P9
P2
P10
3P
P3
P4
P8
P9
P2
P10
Change screens by using the scrolling and selection wheel.
When the wheel is rotated clockwise, the screens scroll upwards and vice-versa.
The screens scroll in a loop.
E.g.: On three-phase + neutral network, then screen 7, then screen 1 and vice-versa.
50/209
2P+N
P3
P6
P8
P9
P2
P10
1P+N
P3
P7
P9
P2
P10
6.3.1.6.
Display of messages in zone 4
The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as
follows:
Initialisation of TELYS
Screen no.
Screen
Data displayed
Initialisation of TELYS when the power is switched on
and/or when loading a configuration
G1
G2
SERIAL No.: 08030010000
SOFTWARE: 6.1.0
NOMINAL VOLTAGE: 400V
FREQUENCY: 50Hz
NOMINAL KW: 320kW
EARTH SYSTEM: TNS
Generating set serial no.
Software version of TELYS
Alternator Nominal Voltage
Alternator Nominal Frequency
Nominal Active Output
Neutral Point
Bar graph indicating the display delay of the screen
51/209
Generating set stopped
Screen no.
Screen
Data displayed
OPERATION
MANUAL
G3
Operating mode - generating set in Manual Mode ready to
start
Date and time (depending on settings)
Press START
to start
24/08/2005
13:12
OPERATION
AUTO
G4
WARNING
START-UP POSSIBLE
IMMEDIATELY
24/08/2005
Operating mode - generating set in Auto Mode ready to
start
Date and time (depending on settings)
13:12
WARNING
G5
Operating mode - generating set in Auto Mode with
programmed start
Countdown to micro disconnection delay or EJP notice
delay (for France only)
Date and time (depending on settings)
AUTOMATIC Start
19 min 30 sec
24/08/2005
13:12
52/209
Generating set start-up
Screen no.
G6
Screen
Data displayed
START-UP
IN PROGRESS
24/08/2005
Operating phase - generating set in starting phase
Date and time (depending on settings)
13:12
AIR PREHEATING
Operating phase - air preheating prior to starting generating
set
Countdown for air preheating delay
Date and time (depending on settings)
G7
10 seconds
24/08/2005
13:12
Generating set started
Screen no.
Screen
Data displayed
AVAILABLE POWER
G8
Default
screen
Operating phase – generating set in operation – stable
voltage and frequency
Available power
Date and time (depending on settings)
75%
24/08/2005
13:12
AUTOMATIC STOP
IN PROGRESS
G9
Operating mode - operation in Auto Mode
Opening of power supply device (motorised circuit breaker
or source changeover switch controlled by TELYS)
Countdown for the mains return delay OR the load test
delay
Date and time (depending on settings)
LOAD SUPPRESSION
1 min 30 sec
24/08/2005
13:12
AUTOMATIC STOP
IN PROGRESS
G 10
Operating mode - operation in Auto Mode
Generation set cooling in progress
Countdown for Engine Stop delay (cooling) OR Gradual
Stop delay (Coolant temperature) OR Overload Gradual
Stop delay OR OFF load test delay
Date and time (depending on settings)
COOLING DOWN
1 min 30 sec
24/08/2005
13:14
53/209
Generating setstop
Screen no.
G 11
Screen
Data displayed
OFF
IN PROGRESS
24/08/2005
Generating set stop in progress
Date and time (depending on settings)
13:16
Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand)
Screen no.
G 12
Screen
Data displayed
Start Demand
AUTO
Do you wish to change
to Auto Mode?
WARNING
Immediate start
OK
Operating mode - operation in Manual Mode
AUTOMATIC start demand
Esc
Generating set stop request due to fault or by pressing STOP in Auto Mode
Screen no.
Screen
Data displayed
Manual Mode
activated
G 13
Do you wish to change
to AUTO mode?
OK
Operating mode - operation in Auto Mode (generating set in
operation)
Warning message for switching to Manual Mode after the
STOP button has been pressed or a fault has appeared
Esc
54/209
6.3.2 Starting
Check that the generating set circuit breaker has triggered.
Danger
Connect the generating set battery
Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not light
up, check and replace the fuse if necessary)
Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS)
1 ACTIONS
1/5
11 MANUAL <> AUTO
12 CONTROL LOAD
13 TEST GENERATING SET
14 PROGRAMS
15 TEST LAMPS
12
OK
Esc
Press "Esc" several times to return to the following home menu
OPERATION
MANUAL
Press START
to start
24/08/2005
13:12
Check the battery voltage
Press START:
AVAILABLE POWER
AIR PREHEATING
START-UP
IN PROGRESS
100.0%
10 seconds
13:12
If the engine is equipped with an air
preheating system, there is a delay
(adjustable) before the engine starts
(preheating activation period).
If the motor is not fitted with an air
preheating system or once the
preheating delay has elapsed, the
engine starts up (start of a cycle
comprising 3 attempts to start up the
engine).
24/08/2005
13:12
Warning: the number of successive and
automatic starting attempts is limited to 3.
24/08/2005
13:12
The following pictogram is displayed
The following pictogram will flash
The following information is displayed
Speed of rotation
Coolant temperature
Oil pressure
Oil Temperature
55/209
Options
24/08/2005
6.3.3 Switching off
Open the circuit breaker
manually
OR
by selecting menu 12 "CONTROL LOAD"
The following display will disappear (supply stopped)
Press the STOP button
The following screen is displayed and the generating set will stop
OFF
IN PROGRESS
24/08/2005
13:12
Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position).
56/209
6.3.4 Alarms and faults
6.3.4.1.
Viewing alarms and faults
Alarms and faults are displayed as follows:
Alarms
All alarms will cause:
the yellow LED to flash "General alarm".
In conjunction with this LED:
a flashing pictogram appears on the LCD screen
representing the circuit affected by the alarm and the
associated indicator, if present
(example)
message on graphic display
(example)
FAULT
ALARM
Low Fuel Level
25/12/05 15:30
OK=HELP
Faults
All faults will cause:
the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit)
the red LED to flash "General fault".
In conjunction with this LED:
a flashing pictogram appears on the LCD screen
representing the circuit affected by the fault and the
associated indicator, if present
(example)
message on graphic display
(example)
FAULT
FAULT
Oil Pressure
25/12/05 15:30
OK=HELP
Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the
oldest).
57/209
6.3.4.2.
Activation of an alarm or fault
The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below)
FAULT
FAULT
ALARM
Low coolant Level
06/10/06 10:30
FAULT
Emergency Stop
06/10/06 15:30
Esc=RESET
OK=HELP
OK=HELP
Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below)
HELP
Check the level
fuel
Esc=EXIT
If the alarm is no longer active, it is reset automatically (cause disappears).
Press Esc to reset a fault:
reset acknowledged if the cause of the fault has been removed
reset not performed if the cause of the fault is still present.
58/209
6.3.4.3.
Activation of an alarm and a fault
The appearance of an alarm and a fault causes:
The yellow and red LEDs to flash
the related screen to be displayed (example below)
FAULTS 1/2
FAULT
Emergency Stop
25/12/05 15:30
Esc=RESET
If several faults are present, the number of faults is displayed at
the top of the screen.
OK=LIST
The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below)
FAULTS
1/2
FAULT 25/12/05 15:30
Emergency Stop
ALARM 25/12/05 15:30
Low Fuel Level
12
OK=HELP
Press Esc to return to the previous screen.
Press OK to go to the HELP screen (help on the highlighted
fault)
Use the scrolling and selection wheel to scroll through the list of
faults.
Esc
HELP
Check:
- Emerg. Stop Pos.
- Connector(s)
Esc
If the alarm is no longer active, it is reset automatically (cause disappears).
Press Esc to reset a fault:
reset acknowledged if the cause of the fault has been removed
reset not performed if the cause of the fault is still present.
59/209
6.3.4.4.
Engine fault codes display
Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587
standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable).
Terminology used by the SAE CAN J1939 standard
SPN: Suspect Parameter
Number
This represents the system or component at fault, for example: SPN 100, indicates an oil
pressure problem or a problem with the oil pressure sensor.
FMI: Failure Mode identifier
This represents the type of fault that has occurred. This may be an electrical, mechanical or
equipment fault.
Terminology used by VOLVO
SID: System Identifier
This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN).
However, this term corresponds, more particularly, to an assembly of components, for
example, the injection system.
PID: Parameter Identifier
This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN).
However, this term corresponds, more particularly, to a specific component, for example, a
sensor.
PPID: Parameter Identifier
This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN).
PPID corresponds to PID, but is only used by VOLVO.
FMI: Failure Mode identifier
This represents the type of fault that has occurred. This may be an electrical, mechanical or
equipment fault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI combination.
Terminology used by PERKINS
CID: Component parameter
This term used by PERKINS has an equivalent in the J1939 standard (SPN).
FMI: Failure Mode identifier
This represents the type of fault that has occurred. This may be an electrical, mechanical or
equipment fault.
Terminology used by JOHN DEERE
SPN: Suspect Parameter
Number
This represents the system or component at fault, for example: SPN 100, indicates an oil
pressure problem or a problem with the oil pressure sensor.
FMI: Failure Mode identifier
This represents the type of fault that has occurred. This may be an electrical, mechanical or
equipment fault.
Terminology used by MTU
Displaying faults
The ADEC and MDEC general system faults are indicated on the equipment in the following
way: fault code numbers (generated by the ECU - Engine control unit).
60/209
In the event of a fault, the screen will display the following message:
FAULT
ALARM
ENGINE GENERAL 110 18
25/12/2005 15:30
OK=HELP
Engine fault code.
Pressing OK will display fault finding information.
In addition, appendix D indicate the meaning of the code. The
checking and maintenance operations to carry out in order to
solve the fault are included in the user and maintenance
manuals of the engines supplied with the generating set
documentation.
For JOHN DEERE (JD), PERKINS (PE) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes.
6.3.4.5.
Horn reset
Depending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the horn sounding and the
following screen appearing:
HORN STOP
PRESS OK
25/12/2005
This screen will display first any messages relating to the
alarms and faults that appear as soon as OK is pressed.
15:30
61/209
7. Maintenance schedule
7.1.
Reminder of use
The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline.
N.B. the environment in which the generating set is operating determines this schedule.
If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed
These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given
in this manual.
7.2.
Engine
Component
Operation
Engine
Oil level
Coolant
Before
starting
●
●
●
First 100 200 hours
50
hrs
6 months
50 - 600
hrs
500 hrs
Check the sealing (1)
Check and Top up
Check the level
Check the outside and
Radiator
●
clean
Check the clogging
Air filter
●
indicator (1-2)
Tighten to 50Nm (36.88
Injectors
●
lbf ft)*
Valve clearance
Check/adjust *
●
Check the electrolyte
Batteries
●
level
Drain the water and
Fuel pre-filter
●
sediment
Coolant filter
Replace (3)
●
Engine oil
Drain (4)
●
Oil filter
Replace
●
Drive belts
Check the voltage
●
* Operation to be carried out by one of our agents.
(1) When operating continuously, the check must be carried out at least every 8 hours.
(2) The air filters must be replaced when the indicator stays in the red zone after the engine is stopped. Special air filters must be
used for extremely dusty conditions.
(3) The filter must never be replaced when the coolant is drained.
(4) The oil service intervals vary depending on the oil grade and the fuel sulphur content (see engine appendix).
Component
Operation
1000
hrs
●
1500 hrs
Check that they
are sealed
Fuel filter
Replace
●
Valve clearance
Check/adjust *
●
Air filter
Clean (5)
Carry out a
Engine and equipment
general check*
Turbocharger
Check*
Injectors
Check*
Coolant
Replace
* This operation should be carried out by one of our agents.
(5) In extremely dusty conditions, cleaning must be carried out more often.
Air ducts
7.3.
2000 hrs
2400 hrs
3000 hrs
5000 hrs
●
●
●
●
●
Alternator
After 20 hours in operation, check the tightness of all the mounting bolts, the general condition of the machine and the various
electrical connections of the installation.
The bearings fitted on the machine are greased for life to around the service life of the grease (depending on use) = 20 000
hours or 3 years.
Regularly clean the inlet and outlet grid.
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8. Battery
Fit the battery so that it is properly ventilated.
Maintenance should only be carried out by qualified personnel.
If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire.
Only use insulated tools (the operator should not be wearing a watch, chain or any metal object).
Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid.
Batteries release oxygen and hydrogen gas, which are flammable.
Never bring flames or sparks near the battery (risk of explosion).
Discharge any static electricity before handling the batteries by first touching an earthed metal surface.
Do not use the battery when the fluid level is below the minimum required level Using a battery with a low
electrolyte level could result in an explosion.
Do not short the battery terminals with a tool or other metal object.
When disconnecting battery cables, remove the cable from the negative (-) terminal first. When reconnecting the
battery, connect the positive lead (+) first.
Charge the battery in a well-ventilated place, with all the filler caps opened.
Ensure that the battery terminals are correctly tightened. A loose cable clamp can cause sparks that could result in
an explosion.
Before servicing electrical components or performing electric welding, set the battery switch to the [OFF] position
or disconnect the battery negative cable (-) to cut off the electrical current.
Electrolyte contains dilute sulphuric acid. Careless handling of the battery causing contact with sulphuric acid
could damage your eyesight or cause burns.
Wear safety goggles and rubber gloves when working with the battery (topping-up fluid, charging, etc.)
If electrolyte comes into contact with your skin or clothes, wash it off immediately with plenty of water, then
carefully wash the area with soap.
Danger
If electrolyte comes into contact with your eyes, rinse immediately with plenty of water and seek medical attention
as soon as possible.
If electrolyte is accidentally swallowed, gargle with plenty of water and drink large quantities of water. Consult a
doctor immediately.
Large quantities of electrolyte should be rinsed off using a neutralising agent. A common method is to use a
solution of 500g of bicarbonate of soda diluted in 4 litres of water. The bicarbonate of soda solution should
be added until the reaction has finished (lather). The remaining liquid should be rinsed off with water and left
to dry.
Dry batteries do not require any servicing
Batteries ready for use must be recharged at the latest when the acid density drops below 1.20.
8.1.
Storage and transport
Batteries ready for use must be stored in a cool and dry place (frost-free) protected from the sun (self-discharge).
Batteries must be transported and stored vertically (risk of acid spillage)
Leave the terminal cover on the positive terminal
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8.2.
Battery setting into service
Batteries filled with acid have a density of 1.28 g/ml and are charged.
In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the
battery rest for 20 minutes.
Before fitting the battery, stop the engine and any power consumer, clean the terminals and give them a light coating of grease.
When connecting, connect the positive terminal (+) first, and then the negative terminal (-).
8.3.
Check
Acid density
1.27
1.25
1.20
1.19
1.13
Charge status
100%
80%
60%
40%
20%
Voltage when idle
Above 12.60 V
12.54 V
12.36 V
12.18 V
Under 11.88 V
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From 50 % recharge
Risk of sulphation
Unusable
8.4.
Load preconization
Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard and
insoluble to acid; this deposit reduce the active surface of the plates, and increases their internal resistance) can no longer
regenerate or be charged in a generating set.
A discharged battery should be recharged immediately, or else it will suffer irreparable damage.
Important
Battery charge
When several batteries are connected together, the following points should be checked:
Are the batteries connected in series?
Has the correct voltage been chosen? 1 battery x 12 V , 3 x 36V batteries.
Adjust the charge current to the lowest battery.
The power difference between the batteries must be as low as possible.
Example of charge:
12V 60 Ah battery = charging current 6 A.
Charge status: 50% (acid density 1.21/voltage when idle 12.30V).
The battery is short 30 Ah, and this must be recharged.
Charge factor: 1.2.
Ah x 1.2 = 36 Ah to be charged.
Charging current: 6A approximately 6 hours charging required.
Recharging is complete when the battery voltage and the acid density stop increasing.
th
→ The charging current must always be 1/10 of the nominal capacity of the battery.
The power of the charger must be suitable for the battery to be charged and the charging time available.
You need to use an automatic charger able to provide a sufficient voltage and charging current, as well as a compensation voltage
to handle spontaneous battery discharge.
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8.5.
Faults and remedies
Fault observed
The acid heats up when a new battery is
filled
The acid escapes through the filler holes
Acid level too low
Acid level too low
Incorrect operation from start-up
Acid density too high
Starting problems
Starting test incorrect
Battery terminals melted
One or two cells release a lot of gas at
high charge
The battery discharges very quickly
Short service life
High water consumption
The battery explodes
-
-
Probable origin
Incorrect composition
Incorrect storage
Prolonged storage in a damp place
Battery overflow during filling
Battery tray not leaktight
Significant gas formation caused by
too high a charging voltage
Insufficient charge
Short circuit in the current circuit
Consumption fault
The battery has been filled with acid
instead of water
Battery empty
Battery used up or faulty
Capacity too low
Battery sulphated
Incorrect electrical connection
Incorrect battery wiring
Cell(s) faulty
- Charge status too low
- Short circuit in the current circuit
- High self-discharge (for example:
through electrolyte contamination)
- Sulphation (storage of discharged
battery)
- Incorrect battery part no.
- Too many repeated deep discharges
- Battery stored too long without charge
-
Overload
Charging voltage too high
Spark after battery charging
Short circuit
Connection or disconnection during
charging
- Internal fault (for example: interruption)
and low electrolyte level
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Measures or observations
Cool
Charge
Check the acid density
Reduce the battery fluid level
Replace the battery
Check the charger and repair if
necessary.
- Recharge
- Check the electrical installation
-
- Reduce the acid level and fill with
distilled water. Repeat the operation if
need be.
- Recharge the battery
- Fit a new battery
- Tighten the ends of the battery cables,
or replace them if necessary
- Fit a new battery
- Check the charge
- Replace the battery
- Define the correct battery part no. for
the recommended use
- Think about charging the battery using
a regulator
- Check the charger (voltage regulator)
- Replace the battery (beware of fire
and sparks)
- Ensure there is sufficient ventilation
9. Appendix
9.1.
Appendix A – Engine user and maintenance manual
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68/209
User's guide and maintenance manual
VOLVO
DIESEL ENGINE
TAD 733
33522077701_0_1
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OPERATOR’S MANUAL
p
Generating set and industrial engines
4-7 liter (EDC 4)
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Foreword
Volvo Penta industrial engines are relied upon throughout the world,
in both mobile and stationary applications, under some of the most
rigorous conditions imaginable. This is not by chance.
After more than 90 years of producing engines the name Volvo Penta
has come to symbolize reliability, technical ingenuity, first-class performance and longevity. We believe that these characteristics are also
ultimately your requirements and expectations for new Volvo Penta
industrial engines.
To make certain that your expectations are matched, we ask that
you read carefully through the instruction book before starting
the engine.
Sincerely
AB VOLVO PENTA
Engine data
Engine designation ...........................
Product number ....................................
Serial number .........................................................................................................
Clutch, type/nr. .......................................................................................................
Nearest Volvo Penta service location
Name ..........................................................................
Telephone ....................
Address ...................................................................................................................
© 2007 AB VOLVO PENTA
Volvo reserves the right to make changes
Printed on environmentally friendly paper
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Table of contents
Safety information ................................................. 2
Safety rules for operation and maintenance .......... 3
Maintenance schedule ........................................ 18
Maintenance schedule ........................................ 18
Introduction ...........................................................
Environmental responsibility .................................
Running in .............................................................
Fuel and oils .........................................................
Maintenance and spare parts ................................
Certified engines ...................................................
Maintenance ........................................................
Engine, general ...................................................
Lubrication system ..............................................
Cooling system ...................................................
Fuel system ........................................................
Electrical system ................................................
6
6
6
6
6
7
Presentation .......................................................... 8
Technical description ............................................ 8
Identification numbers ......................................... 10
EDC 4 ................................................................. 11
20
20
22
25
30
32
Laying up ............................................................. 36
Conservation ....................................................... 36
Removing conservation preparations ................... 36
Instruments ......................................................... 12
Fault tracing ........................................................ 37
Symptoms and possible causes ......................... 37
Starting the engine ..............................................
Before starting ....................................................
Starting method EDC 4 .......................................
Starting in extreme cold ......................................
Never use start spray ..........................................
Starting with auxiliary batteries ...........................
13
13
13
14
15
15
Diagnostic function .............................................
Diagnostic function .............................................
Malfunction message ..........................................
Fault tracing guide ..............................................
Effect on engine ..................................................
Operation ............................................................
Operation .............................................................
Checking instruments .........................................
Fault indication ....................................................
Engine speed control ..........................................
Operation at low load ..........................................
16
16
16
16
16
Fault codes .......................................................... 40
Stopping the engine ...........................................
Before stopping ...................................................
Stop ....................................................................
After stopping .....................................................
17
17
17
17
Technical data .....................................................
General ...............................................................
Lubrication system ..............................................
Fuel system ........................................................
Cooling system ...................................................
Electrical system ................................................
38
38
38
38
38
39
46
46
49
50
51
51
1
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Safety information
Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and
looking after the engine.
Check that you heave received the correct instruction book before you read on. If not, please contact your
Volvo Penta dealer.
Incorrect operation can lead to personal injury and damage to products or property. So read the
instruction book through very carefully before you start the engine or do any maintenance or service work. If there is still something which is unclear or if you feel unsure about it, please contact
your Volvo Penta dealer for assistance.
This symbol is used in the instruction book and on the product, to call your attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the instruction book have the following order of priority:
WARNING! Warns for the risk of personal injury, major damage to product or property, or
serious malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things which could cause damage or malfunctions
to product or property.
NOTE! Is used to call attention to important information, to facilitate work processes or operation.
This symbol is used on our products in some cases and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine are clearly
visible and legible. Replace symbols which have been damaged or painted over.
2
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Safety information
Safety rules for operation and maintenance
Daily checks
Ignition lock
Make it a habit to give the engine and engine bay a visual check before operating (before starting the engine) and after operation (when you have stopped
the engine). This helps you to quickly discover
whether any leakage of fuel, coolant, oil or any other
abnormal event has happened, or is about to happen,.
If the instrument panel does not have a key switch,
the engine room must be lockable, to prevent unauthorized persons from starting the engine. Alternatively, a lockable main switch can be used.
Care and maintenance
Knowledge
Fuel filling
There is always a risk of fire and explosion during fuel
filling. Smoking is not permissible, and the engine
should be stopped.
Never over-fill the tank. Shut the tank cap securely.
Only use the fuel recommended in the instruction
book. The wrong grade of fuel can cause malfunctions
or stop the engine. In a diesel engine, it can also
cause the injection pump to bind and the engine will
over-rev, entailing a strong risk of personal injury and
machinery damage.
The instruction book contains instructions for doing
the most common service and maintenance tasks in a
safe and correct manner. Read them carefully before
starting work.
Literature for more major tasks is available from your
Volvo Penta dealer.
Never do a job if you are not entirely sure about how
to do it. Please contact your Volvo Penta dealer and
ask for assistance instead.
Stop the engine.
Carbon monoxide poisoning
Only start the engine in a well- ventilated area. When
operated in a confined space, exhaust fumes and
crankcase gases must be ventilated.
Operation
The engine must not be operated in environments
which contain explosive media since none of the electrical and mechanical components are explosion
proof.
Going close to a running engine is a safety risk. Hair,
fingers, loose clothes, or dropped tools can catch on
rotating components and cause severe injury.
Stop the engine before opening or removing the engine hatch/hood. Care and maintenance work should
be done with the engine stopped unless otherwise
specified.
Prevent the engine from being started by cutting the
current with the battery isolator, or remove the cable
from the battery positive pole before you start service
work. Fix a notice by the operator’s seat to say that
work is in progress.
Working with, or going close to a running engine is a
safety risk. Hair, fingers, loose clothes, or dropped
tools can catch on rotating components and cause severe injury. Volvo Penta recommends that all service
work which requires the engine to be running should
be done by a Volvo Penta authorized workshop.
When engines are supplied without touch guards, all
rotating components and hot surfaces must be protected after installation in their application, if necessary for personal safety.
3
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Safety information
Safety rules for operation and maintenance (contd.)
Lifting the engine
Batteries
The existing lugs on the engine should be used for lifting. Always check that the lifting devices are in good
condition and that they have the correct capacity for
the lift (engine weight together with auxiliaries, if fitted). The engine should be lifted with an adjustable
lifting boom for safe handling. All chains or cables
should be parallel to each other and should be as
square as possible to the top of the engine. Please
note that auxiliary equipment installed on the engine
could change its centre of gravity. Special lifting devices may then be needed to obtain the correct balance and safe handling. Never do any work on an engine which just hangs from a lifting devise.
Batteries contain and give off an explosive gas, especially when charged. This gas is very flammable and
highly explosive.
Before starting
Smoking, open flames or sparks must never occur in
or near to batteries or the battery locker.
Incorrect connection of a battery cable or start cable
can cause a spark which can be sufficient, in its turn,
to make the battery explode.
Start spray
Never use start spray or similar preparations to help in
starting an engine with air pre-heating (glow plugs /
starting heater). Explosions could occur in the inlet
manifold. Danger of personal injury.
Re-install all guards which have been removed during
service work, before re-starting the engine. Make sure
that there are no tools or other objects left behind on
the engine.
Never start a turbocharged engine without the air filter
in place. The rotating compressor turbine in the turbocharger can cause severe injury. There is also a risk
that foreign bodies could be sucked in and cause machinery damage.
Hot surfaces and fluids
A hot engine always offers the risk of burns. Be on
your guard against hot surfaces: the exhaust manifold, turbocharger, oil pan, charge air pipe, starting
heater, hot coolant and hot lubricating oil in pipes,
hoses etc.
Fire and explosion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are
flammable. Always read and observe the advice on
the packages.
Chemicals
Most chemicals, such as glycol, rust preventer, conservation oils, degreasers etc. are hazardous. Always
read and observe the advice on the packages.
Work on the fuel system must be done with the engine cold. Fuel leakage and spills on hot surfaces or
electrical components can cause fires.
Some chemicals, such as conservation oils, are flammable and also hazardous to breathe. Ensure good
ventilation and use a protective mask for spraying. Always read and observe the advice on the packages.
Store oil and fuel soaked rags and other flammable
material in a fire-proof manner. Oil soaked rags can
self-ignite in certain circumstances.
Store chemicals and other hazardous material out of
the reach of children. Hand in surplus or used chemicals to a recycling station for destruction.
Never smoke when filling fuel, lubrication oil or close
to fuel filling stations or the engine bay.
Lubrication system
Non-original spare parts
Components in fuel systems and electrical systems
on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fire, in accordance with applicable legal requirements.
Hot oil can cause burns. Avoid skin contact with hot
oil. Make sure that the oil system is de-pressurized
before starting work. Never start or run the engine with
the oil filler cap removed, because of the risk of oil
spillage.
The use of non-original spare parts can cause an explosion or fire.
4
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Safety information
Electric welding
Cooling system
Avoid opening the coolant filling cap when the engine
is hot. Steam or hot coolant can spray out at the
same time as the pressure built up is lost.
Remove the positive and negative cables from the
batteries. Then disconnect all cables connected to the
alternator.
If the filler cap, coolant hose etc., still has to be
opened or removed when the engine is hot, undo the
filler cap slowly and carefully, to let the pressure out
before removing the filler cap completely and starting
work. Note that the coolant can still be hot and cause
scalding.
Always connect the welder earth clamp to the component to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
When welding is completed: Always connect the alternator cables before the battery cables are put
back.
Fuel system
Always protect your hands when searching for leaks.
Fluids which leak under pressure can force their way
into body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Always cover the alternator if it is located beneath the
fuel filters. Fuel spillage can damage the alternator.
Electrical system
Cut the current
Before any work is done on the electrical system, the
engine must be stopped and the current cut by switching off the main switch(es). External current supply for
engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be disconnected.
Batteries
Batteries contain a highly corrosive electrolyte. Protect your eyes, skin and clothes during charging and
other handling of batteries. Always use protective goggles and gloves.
If acid comes into contact with your skin, wash at
once with soap and a lot of water. If you get battery
acid in your eyes, flush at once with a lot of cold water, and get medical assistance at once.
5
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Introduction
This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial
engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.
Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a safe
manner before you start the engine.
IMPORTANT! This instruction book describes the engine and equipment sold by Volvo Penta. Variations in
appearance and function of the controls and instruments may occur in certain variants. In these cases,
please refer to the instruction book for the relevant application.
Environmental responsibility
Fuel and oils
All of us want to live in a clean, healthy environment,
where we can breathe clean air, see healthy trees,
have clean water in lakes and seas, and be able to
enjoy the sunlight without fearing for our health. Unfortunately, this is not self-evident these days, it is
something all of us must work for.
Only use the fuels and oils recommended in the instruction book (please refer to the “Maintenance”
chapter under the fuel and lubrication system headings). Other grades of fuel and oils can cause malfunctions, increased fuel consumption and eventually
even shorten the life of the engine.
As an engine manufacturer, Volvo Penta has particular responsibility and for this reason, environmental
care is a self-evident foundation of our product development. Volvo Penta has a wide engine program
these days, where considerable progress has been
made in reducing exhaust fumes, fuel consumption,
engine noise etc.
Always change the oil, oil filter and fuel filter at the
specified intervals.
We hope that you will be want to preserve these values. Always observe the advice in the instruction
book about fuel grades, operation and maintenance, to
avoid unnecessary environmental impact. Please contact your Volvo Penta dealer if you notice any changes such as increased fuel consumption or increased
exhaust smoke.
Please remember to always hand in hazardous waste
such as drained oil, coolant, old batteries etc. for destruction at an approved recycling facility.
If we all pull together, we can make a valuable contribution to the environment together.
Running in
Maintenance and spare parts
Volvo Penta engines are designed for maximum reliability and long life. They are built to withstand a demanding environment, but also to have the smallest
possible environmental impact. Through regular service and use of Volvo Penta original spare parts,
these qualities are retained.
Volvo Penta has a world-wide network of authorized
dealers. They are Volvo Penta product specialists,
and have the accessories, original spares, test equipment and special tools needed for high quality service
and repair work.
Always observe the maintenance intervals in the
instruction book, and remember to note the engine/transmission identification number when you
order service and spare parts.
The engine must be “run in” during its first 10
hours, as follows:
Use the engine in normal operation. Full load should
only be applied for short periods. Never run the engine
for a long period of time at constant speed during this
period.
Higher oil consumption is normal during the first 100200 hours of operation. For this reason, check the oil
level more frequently than normally recommended.
When an opening clutch is installed, this should be
checked more carefully during the first days. Adjustment may need to be done to compensate bedding in
of the friction plates.
6
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Introduction
Certified engines
•
If you own an emission certified engine, which is
used in an area where exhaust emissions are regulated by law, it is important to be aware of the following:
The engine must not be converted or modified,
except for the accessories and service kits which
Volvo Penta has developed for the engine.
•
No installation changes to the exhaust pipe and
engine air inlet ducts may be done.
•
No seals may be broken by unauthorized
personnel.
Certification means that an engine type has been
checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
This makes special demands on the care and
maintenance you give your engine, as follows:
•
Maintenance and service intervals recommended
by Volvo Penta must be complied with.
•
•
Only Volvo Penta original spares may be used.
The general advice in the instruction book about operation, care and maintenance applies.
IMPORTANT! Delayed or inferior care/
maintenance, and the use of non-original spares,
mean that AB Volvo Penta can no longer be
responsible for guaranteeing that the engine
complies with the certified version.
Damage, injury and/or costs which arise from
this will not be compensated by Volvo Penta.
Service to injection pumps, pump settings and
injectors must always be done by an authorized
Volvo Penta workshop.
Warranty
Your new Volvo Penta industrial engine is covered by a limited warranty, under the conditions and instructions compiled in the Warranty and Service book.
Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Service
book. Read it carefully, as soon as possible after delivery. It includes important information about warranty cards, service intervals, maintenance, which it is the responsibility of the owner to know, check
and carry out. If this is not done, AB Volvo Penta may fully or partly refuse to honor its warranty undertakings.
Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, or
a customer copy of the warranty card.
7
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Presentation
TD420VE, TAD420VE, TD520GE, TAD530/531GE and TAD520VE are in-line, direct injected, 4-cylinder industrial
diesel engines.
TAD620VE, TD720GE, TAD730/731GE, TAD720VE, TAD732GE, TAD721VE, TAD733GE and TAD722VE are inline, direct injected, 6-cylinder industrial diesel engines.
All engines are equipped with electronically controlled fuel management (EDC4), turbocharger, thermostatically
controlled cooling systems and electronic speed control. All TAD engines are also equipped with an intercooler.
Technical description
Engine and engine block
Fuel system
–
The engine block and cylinder head are manufactured of alloyed cast iron
–
Belt driven feed pump - BOSCH injection pump,
one for each cylinder
–
Five bearing, induction hardened crankshaft
(TD420VE, TAD420VE, TD520GE, TAD530/
531GE, TAD520VE, TAD532GE)
–
HEINZMANN actuator
–
EDC 4 (Electronic Diesel Control). Please refer to
a separate description.
Seven bearing, induction hardened crankshaft
(TAD620VE, TD720GE, TAD730/731GE,
TAD720VE, TAD732GE, TAD721VE, TAD733GE,
TAD722VE)
–
Replaceable wet cylinder liners (TD520GE,
TAD530/531GE, TAD520VE, TD720GE, TAD730/
731GE, TAD720VE, TAD732GE, TAD721VE,
TAD733GE, TAD722VE, TAD532GE)
Replaceable dry cylinder liners (TAD620VE)
Liner-less (TD420VE, TAD420VE)
–
Cast aluminum pistons with oil cooling
–
Three piston rings, with a “keystone” type top ring
–
Induction hardened overhead camshaft with valve
lifters and push rods.
–
Two valves per cylinder
–
Replaceable valve seats and valve guides (does
not apply to TD420VE, TAD420VE, TAD620VE)
Lubrication system
–
Water cooled oil cooler.
–
Crankshaft driven lube oil pump
–
Full flow filter with bypass
Turbocharging system
– Turbocharger
Cooling system
– Radiator with expansion tank
– Air cooled intercooler (TAD)
Electrical system
– 24 V (standard), 12 V (option)
Control unit
–
Microprocessor based fuel supply control unit
(EDC 4)
–
Maximum ambient temperature 80° C
–
Automatic sensing of 24 V or 12 V.
–
Atmospheric pressure sensor for high altitude applications (option)
8
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Presentation
TD420VE, TAD420VE, TAD620VE
TD520GE, TAD530GE, TAD531GE, TAD532GE, TAD520VE
TD720GE, TAD730/731GE, TAD732/733GE
TAD720VE, TAD721VE, TAD722VE
9
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Presentation
Identification numbers
Location of engine signs
The engines are supplied with two engine signs, of
which one is installed on the right side of the engine
block.
Engine plate
1.
2.
3.
4.
5.
6.
7.
8.
Engine model
Engine specification number
Engine series number (10 digits)
Engine power, peak, without fan
Engine speed
Injection advance and type of camshaft
Manufacturer’s identification code
Indication of standard and/or specification
9. Air temperature in °C (°F), in accordance with ISO
3046
10. Altitude above mean sea level, in accordance
with ISO 3046
11. EP code for injection pump (cylinder 1 on top)
12. Piston class
13. Extra information
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Presentation
EDC 4
EDC 4 (Electronic Diesel Control) and is an electronic system with CAN (Controller Area Network) or potentiometer communication for diesel engine control. The system includes fuel management and diagnostic functions.
Summary
Diagnostic function
The system includes sensors, control unit and an engine speed regulator. The sensors send input signals
to the control unit, which controls the control rod for
the injection pumps in its turn, by means of an actuator in the engine speed regulator.
The task of the diagnostic function is to discover and
localize any malfunctions in the EDC 4 system, to
protect the engine and to ensure operation in the
event of serious malfunctions.
Input signals
The control unit receives input signals about engine
operating conditions from the following components:
–
speed sensor, camshaft
–
coolant temperature sensor
–
charge pressure sensor
–
oil pressure sensor
–
fuel temperature sensor
–
coolant level sensor (the function is implemented
in the control unit as standard, but no sensor is
supplied with the engine as a standard feature)
If a malfunction is discovered, this is notified by the
diagnostic function, by warning lamps or via the CAN
network. By pressing the diagnostic switch, the operator will receive a fault code as a guide for any faulttracing. Fault codes can also be output via the CAN
interface or with Volvo’s VODIA tool (including the
Penta EDC4 software) at an authorized Volvo Penta
workshop.
If there is a serious malfunction, the engine is shut
down altogether. Yet again, fault codes can be output
via diagnostic connector, the CAN interface or with
Volvo’s VODIA tool (including the Penta EDC4 software) at an authorized Volvo Penta workshop.
Output signals
The control unit controls the following components on
the basis of the input signals received:
–
engine speed regulator (with position sensor for
the control rod and acutator)
–
electric air pre-heating (option)
Information from the sensors provides exact information about current operation conditions and allows the
processor to calculate the correct fuel volume, check
engine status etc.
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Instruments
The engines are not supplied with instruments and
controls. The choice of instrument type and controls
is made by the customer.
The functions available are described below.
A. Engine speed potentiometer (throttle control)
B. CAN interface SAE J 1939
C. VODIA input
D. Droop contact
E. 1500 / 1800 rpm switch
F. Diagnostic button
G. Tachometer
H. Warning lamp, oil pressure
J. Diagnostic lamp
K. Warning lamp, high coolant temperature
L. Fuse 15 A
M. Main switch
N. Battery (24(12 V).
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Starting the engine
Make it a habit to check the engine and engine room before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments show normal values after starting.
Before starting
•
Check that the oil level is between the MAX and
MIN marks. Please refer to the “Maintenance, lubrication system” chapter:
•
•
Open the fuel taps.
•
Check the air filter pressure drop indicator. Please
refer to the “Maintenance, Engine, general” chapter:
•
Check the coolant level and that the radiator is not
blocked externally. Please refer to the “Maintenance, cooling system” chapter:
Check that there is no leakage of oil, fuel or coolant.
WARNING! Do not open the expansion tank cap
when the engine is hot. Steam or hot fluid could
spray out.
•
Turn the main current on.
IMPORTANT! Never disconnect the current with
the main switch(es) when the engine is running.
This will damage the alternator.
•
Move the engine speed control to idle, and release
the opening clutch/gearbox if installed.
Starting method EDC 4
The engine speed lever must always be in neutral before starting. The EDC4 system ensures that the engine always receives the correct amount of fuel - even
when the engine is cold!
Start the engine.
If the engine is equipped with a pre-heater, the preheating time is adjusted to suit the engine temperature.
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Starting the engine
Starting in extreme cold
Certain preparations must be made to facilitate engine
starting, and in some cases to make starting possible
at all.
Use a winter grade fuel (of a well-known make) which
has been approved for the relevant temperature. This
reduces the risk of wax deposits in the fuel system.
At extremely low temperatures, the use of a fuel heater is recommended.
For fully acceptable lubrication, a synthetic engine oil
of recommended viscosity for the relevant temperature should be used. Please refer to the “Maintenance,
lubrication system” chapter: Synthetic lubricants are
able to manage a wider temperature range than mineral-based lubricants.
Pre-heat the coolant with a separately installed electric engine heater. In extreme cases, a diesel-burning
engine heater may be needed. Ask your Volvo Penta
dealer for advice.
IMPORTANT! Make sure that the cooling system is filled with a glycol mixture. Please refer to
the “Maintenance, cooling system” chapter:
The batteries should be in good condition. Cold weather reduced battery capacity. Increased battery capacity may be necessary.
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Starting the engine
Never use start spray
WARNING! Never use start spray or similar products as a starting aid. Explosions could occur in
the inlet manifold. The consequence could be
personal injury.
Starting with auxiliary batteries
WARNING! Batteries (especially auxiliary batteries) contain hydrogen which is highly explosive
in contact with air. A spark, which can be formed
if the auxiliary batteries are wrongly connected,
is enough to make a battery explode and cause
damage.
1. Check that the auxiliary batteries are connected
(series or parallel) so that the rated voltage corresponds to the engine system voltage.
2. First connect the red (+) jumper cable to the auxiliary battery, then to the flat battery. Then connect
the black jumper cable (–) to the auxiliary battery,
and lastly to a place some distance from the flat
batteries, such as the negative cable by the main
switch or the negative cable connection on the
starter motor.
3. Start the engine.
WARNING! Do not move the connections when
you attempt to start the engine (risk of arcing),
and do not stand and lean over one of the batteries.
4. Remove the jumper cables in the reverse order
from installation.
WARNING! The ordinary cables to the standard
batteries must not be loosened on any condition.
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Operation
Correct operation technique is very important for both fuel economy and engine life. Always let the engine warm
up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at
high engine speeds.
Checking instruments
Engine speed control
Check all instruments directly after starting, and then
regularly during operation.
Avoid sudden and violent throttle opening.
IMPORTANT! The lubrication oil level must be
checked every 8 hours on engines which operate continuously. Please refer to the “Maintenance, lubrication system” chapter:
Fault indication
If the EDC4 system receives abnormal signals from
the engine, the “Diagnostic lamp” will start to flash. By
pressing the “Diagnostic button”, a fault code can be
received which can guide fault tracing (or a fault code
can be received via the CAN network).
More information about fault codes and fault tracing is
found in the “Diagnostic function” chapter.
Effect on engine
The diagnostic function affects the engine in the following ways:
Operation at low load
Avoid long-term operation at idle or at low load, since
this can lead to increased oil consumption and eventually to oil leakage from the exhaust manifold, since
oil will seep past the turbocharger seals and accompany the induction air into the inlet manifold at low turbo
boost pressure.
One consequence of this is that carbon builds up on
valves, piston crowns, exhaust ports and the exhaust
turbine.
At low load, the combustion temperature is so low that
full combustion of the fuel can not be ensured, which
means that the lubrication oil can be diluted by diesel
fuel, and the exhaust manifold will eventually leak oil.
If the following points are done as a complement
to normal maintenance, there will be no risk of
malfunctions caused by operation at low load.
•
engine is regularly test run without load once a
week, operation duration should be limited to 5
minutes.
1. The diagnostic function has discovered a minor
malfunction which does not damage the engine.
Reaction: The engine is not affected. The diagnostic lamp lights up.
Reduce operation at low load to a minimum. If the
•
Run the engine at full load for about 4 hours once
a year. This gives carbon deposits in the engine
and the exhaust pipe a chance to be burned away.
2. The diagnostic function has discovered a serious
malfunction which will not immediately damage
the engine (e.g. high coolant temperature):
Reaction: The engine goes into “limp home”
mode. The diagnostic lamp lights up.
3. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
the engine.
Reaction: The diagnostic lamp starts to flash. Engine is shut off.
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Stopping the engine
During longer breaks in operation, the engine must be warmed up at least once every fortnight. This prevents corrosion damage in the engine. If you expect the engine to be unused for two months or more, it must be laid up:
Please refer to the “Laying up” chapter.
IMPORTANT! If there is a risk of frost, the coolant in the cooling system must have sufficient frost protection. Please refer to the “Maintenance, cooling system” chapter: A poorly charged battery can freeze and
burst.
Before stopping
Allow the engine to run for a few minutes without load
before stopping it. This permits the temperature inside
the engine to even up, “after-boiling” is avoided, at the
same time as the turbocharger cools somewhat. This
contributes to long service life without malfunctions.
Stop
•
•
Disengage the clutch (if possible).
Depending on the equipment installed; press the
stop button and keep it depressed until the engine
has stopped, or turn the key to the stop position.
Release the key when the engine has stopped.
After stopping
•
•
Check the engine and engine bay for leakage.
•
Carry out maintenance in accordance with the
schedule.
Turn off the main switches before any long stoppage.
WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.
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Maintenance schedule
General
It is important that the engine receives regular care & maintenance, to achieve maximum reliability and service
life. By following the service recommendations, engine performance is sustained and unnecessary environmental
impact is avoided.
MAINTENANCE SCHEDULE
WARNING! Before you start to do any maintenance work, read the “Maintenance”
chapter carefully. This contains instructions for doing work in a safe and correct manner.
IMPORTANT! When both operation and calendar time are specified, do the
maintenance job at the interval which is reached first. Maintenance points marked
must be done by an authorized Volvo Penta workshop.
Daily, before first start
•
•
•
•
•
Engine oil, level check 1) .............................................................................. page 23
Coolant, level check .................................................................................... page 26
Radiator, external checking and cleaning ..................................................... page 28
Air filter indicator, inspection 1, 2, 3) ................................................................. page 20
Leakage check, engine ............................................................................. not shown
1)
In continuous operation, checks should be done every 8 hours.
The air filter should be changed when the indicator remains in the red field after the engine has been stopped.
3)
When operated in extremely dirty conditions, special air filters must be used.
2)
After the first 100-200 hours
Valve clearance, check ............................................................................. not shown
Injectors, re-tighten 50Nm (36.88 lbf ft) ..................................................... not shown
Every 50 hours
•
•
1)
Battery, checking the electrolyte level ......................................................... page 32
Release bearing, lubrication 1) ................................................................... not shown
Applies to a disconnection clutch with more than 15-20 clutch operations per day. Otherwise, every 400
hours.
Every 6 months
•
1)
Coolant filter, change 1) ............................................................................. not shown
The filter should not be changed when the coolant is changed, however.
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Maintenance schedule
Every 50-600 hours or at least every 12 months
•
1)
Engine oil and oil filter, change 1) .............................................................. page 22-23
Oil change intervals vary, depending on oil grade and sulfur content of the fuel. page 26.
Every 500 hours
•
•
Fuel tank (sludge trap), drain ..................................................................... not shown
Drive belts, inspection/adjustment .............................................................. page 21
Every 1000 hours
•
•
Air hoses, leakage check ............................................................................. page 20
Fuel filter, changing ...................................................................................... page 29
Every 1500 hours
Valve clearance, inspection/adjustment .................................................... not shown
Every 2000 hours or every 12 months
•
•
1)
Air filter for air compressor, change .......................................................... not shown
Air filter, clean (TAD engines) 1) ................................................................. not shown
When operated in extremely dirty conditions, it must be cleaned frequently.
Every 2400 hours
Turbocharger, check ................................................................................. not shown
Engine with equipment, general check ...................................................... not shown
Every 3000 hours
Injectors, check ........................................................................................ not shown
Every 5000 hours or at least every 24 months
•
Coolant, change ...................................................................................... page 24-25
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Maintenance
This chapter describes how the specified maintenance points should be done. Read them carefully before starting
work. The times when maintenance points need to be attended to are given in the previous chapter: Maintenance
schedule
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work.
WARNING! Care and maintenance work should be done with the engine stopped unless otherwise specified.
Make it impossible to start the engine by removing the ignition key and cutting the system voltage with the
main switch. Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.
Engine, general
Air filter Check/change.
Change the air filters when the indicator remains in the
red field after the engine has been stopped. Reinstate
the pressure drop indicator after changing the filter, by
pressing in the button.
NOTE! The filters should not be touched until the indicator shows the red field. Scrap the old filters. No
cleaning or re-use may be done.
IMPORTANT! In continuous operation, the filters
should be checked every 8 hours.
When operated in extremely dirty conditions,
such as coal mines, stone crushing mills etc.,
special filters are needed (not sold by Volvo Penta).
Air hoses. Leakage check.
Inspect the condition of the hoses, for cracks and other damage. Change as necessary. Test all hose
clamps for tightness.
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Maintenance
Drive belts. Inspection/adjustment
Inspection and any adjustment should be done after
operation, when the belts are hot.
Loosen the screws (A) before tensioning the alternator
belts. It should be possible to press the belts down
about 10 mm (3/16 “) between the pulleys. Worn belts
which operate in pairs should be changed together.
On TD420VE, TAD420VE and TAD620VE, the fan
belts have an automatic belt tensioner and do not
need to be adjusted.
TD520GE, TAD530/531GE, TAD532GE, TAD520VE,
TAD620VE, TD720GE, TAD730/731GE, TAD720VE,
TAD732GE, TAD721VE, TAD733GE and TAD722VE
have mechanical belt tensioners.
Always check the condition of the drive belts. Change
as necessary.
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Maintenance
Lubrication system
Oil change intervals can vary from 40 to 500 hours, depending on oil grade and sulfur content of the fuel. Note
that oil change intervals must never exceed a period of 12 months.
If you want longer oil change intervals than given in the table below, the condition of the oil must be checked by
the oil manufacturers through regular oil testing.
Sulfur content in fuel, by weight
Engine
Oilgrade
< 0,5 %
0,5 – 1,0 %
> 1,0 %1)
Oil change interval, reached first in operation
T(A)D420-620VE
T(A)D520-721VE
T(A)D520-731GE
TAD532GE
TAD732/733GE, open
crankcase ventilation
VDS-3
VDS-2
ACEA: E7, E5, E3
API: CI-4, CH-4, CG-4
500 h / 12 months
250 h / 12 months
125 h / 12 months
TAD732/733GE, closed
crankcase ventilation
ACEA: E4
API: CI-4, CH-4
500 h / 12 months
250 h / 12 months
125 h / 12 months
500 h / 12 months
250 h / 12 months
125 h / 12 months
250 h / 12 months
125 h / 12 months
60 h / 12 months
NOTE! Fully synthetic oil must be used
TAD722VE
power<200kW
power>200kW
ACEA: E4
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
The engine oil must fullfil both requirements. For markets outside Europe, API: CG-4 and CH-4 can be used instead of
ACEA: E3.
2)
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
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Maintenance
Viscosity
Select the viscosity from the table below, for the appropriate continuous ambient air temperature.
* Refers to synthetic or semi-synthetic oils.
Oil change volume
Please refer to the “Technical Data” chapter.
Oil level. Inspection
Make sure that the oil level is between the MAX and
MIN marks.
IMPORTANT! In continuous operation, the oil level should be checked every 8 hours.
WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.
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Maintenance
Oil and oil filters. Change
Always follow the recommended oil change interval
and always change the oil filter during oil changes. On
stationary engines, the bottom plug should not be
removed. Use an oil drain pump to suck the oil up.
1. Clean the oil filter holder thoroughly to avoid dirt
entry when the new filter(s) is/are installed.
2. Warm the engine up.
WARNING! Hot oil and hot surfaces can cause burns.
3. Remove the bottom plug. Drain the oil.
4. Install the bottom plug with a new gasket.
5. Remove the filer (1). Check that the gasket has
not been left behind on the engine.
5. Fill the new filters with engine oil and wipe oil on
the gaskets. Screw the filters on by hand until the
gaskets just touch the mating surface. Then turn
the filter a further half turn. Not more!
6. Fill up with oil to the correct level. Do not fill over
the MAX level.
7. Start the engine and let it idle. Check that the oil
pressure is normal.
8. Stop the engine. Check that no oil leakage occurs
around the filters. Top up with oil as necessary.
Collect the old oil and old filters and hand them to
a re-cycling station for destruction.
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Maintenance
Cooling system
The cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system and
must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freezing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (concentrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is suited
too and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequate
protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines. Never
use water by itself as coolant.
IMPORTANT! Coolant, with a sutiable consistency, must be used all year round. This applies even if there
is never any risk for frost , to ensure that the engine has an adequate protection against corrosion.
Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has
been used or if the instructions concerning coolant mixing have not been followed.
NOTE: The anti-corrosive agents become less effective after a time, which means that the coolant must be replaced, see “Service schematic”. The cooling system should be flushed out at the same time as the coolant is replaced, see “Cooling system. Flushing”.
“Volvo Penta Coolant” is a concentrated coolant
that is to be mixed with water. It has been developed
to function optimally with Volvo Penta’s engines and
provides excellent protection against corrosion, cavitation and frost damage.
“Volvo Penta Coolant, Ready Mixed” is a readymixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (18°F).
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Maintenance
Coolant. Mixture
WARNING! All glycol is hazardous and harmful
to the environment. Do not consume!
Glycol is flammable.
IMPORTANT! Ethylene glycol must not be
mixed with other types of glycol.
Mix:
40 % “Volvo Penta Coolant” (conc. coolant)
60 % water
This mixture protects the engine against internal corrosion, cavitation and frost damage down to -28 °C
(18°F). (Using 60 % glycol lowers the freezing point to
-54 °C (65°F)). Never mix more than 60 % concentrate
(Volvo Penta Coolant) in the cooling liquid, this will
give reduced cooling effect and increase the risk of
overheating, and will give reduced freezing protection.
IMPORTANT! Coolant must be mixed with pure
water, use distilled - de-ionized water. The water must fulfill the requirements specified by
Volvo Penta, see “Water quality”.
IMPORTANT! It is extremely important that the
correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.
Water quality
ASTM D4985:
Total solid particles ...................................... < 340 ppm
Total hardness: ............................................ < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ........................................................... < 100 ppm
pH value ........................................................
5,5– 9
Silica (acc. ASTM D859) .............................. < 20 mg SiO2/l
Iron (acc. ASTM D1068) .............................. < 0.10 ppm
Manganese (acc. ASTM D858) ................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................ < 500 µS/cm
Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l
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Maintenance
Coolant. Checking and filling
WARNING! Do not open the filler cap when the
engine is warm, except in emergencies. Steam
or hot fluid could spray out.
Check the coolant level daily before starting. Top the
coolant up as necessary. The level should be about
50 mm (2”) below the sealing plane of the filler cap, or
between the MIN and MAX markings, if a separate expansion tank is installed.
IMPORTANT! Topping up should be done with
the same type of mixture as is already in the
cooling system.
Filling a completely empty system
Check that all drain points are closed.
The location of drain and vent taps is shown overleaf.
Filling should be done with the engine stationary. Fill
up slowly, to allow the air to flow out.
If a heating unit is connected to the engine cooling
system, the heat control valve should be opened and
the installation vented during filling.
Fill up with coolant to the correct level. Do not start
the engine until the system is vented and completely filled.
Start the engine and warm it up until the thermostats
are fully open (about 20 minutes). Open any venting
taps some while after starting, to allow shut-in air to
escape. Check the coolant level and top up as necessary.
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Maintenance
Coolant. Draining.
The engine must be stopped before draining, and
the filler cap unscrewed.
WARNING! Do not open the filler cap when the
engine is warm, except in emergencies. Steam
or hot fluid could spray out.
Open the drain taps and remove the drain plugs (positions are shown below). Unscrew and empty the coolant filter if installed.
IMPORTANT! Deposits, which must be cleared
away, may be found inside the drain plugs/taps.
Check that all coolant really does drain out.
Drain/vent taps. Location
Drain plugs (P):
– under the radiator
– beside cyl. 3 or cyl. 5 (4 or 6-cylinder engines)
– under the oil cooler
Vent tap (1):
– On the coolant pump
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Maintenance
Cooling system Flushing
Cooling performance is reduced by deposits in the radiator and cooling galleries. The cooling system
should be flushed when the coolant is changed.
1. Drain the coolant, as in the description on the previous paragraph.
2. Insert a hose into the filler hole in the radiator, and
flush with fresh water until the water which runs out
is completely clear.
3. Close the drain taps and plugs. Fill up with fresh
coolant, as in the instructions in the chapter entitled “Coolant. Checking and filling”.
Radiator (air cooled intercooler TAD).
External cleaning
Remove guards as necessary, to access the radiator.
Clean with water and a mild detergent. Use a soft
brush. Be careful not to damage the radiator matrix.
Re-install the components.
IMPORTANT! Do not use a high pressure power
washer.
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Maintenance
Fuel system
Only use the grades of fuel recommended in the fuel specification below. Always observe the greatest cleanliness
during re-fueling and work on the fuel system.
All work on the injection system of the engine must be done by an authorized workshop. If the seal on the injection pump is broken by an unauthorized person, all warranties are void.
WARNING! Fire hazard. Work on the fuel system must be done with the engine cold. Fuel spills on hot surfaces or electrical components can cause fires. Store fuel-soaked rags in a fire-proof manner.
Fuel specification
The fuel must comply with national and international
standards for commercially supplied fuels, such as:
EN590 (with nationally adapted environmental and
cold requirements)
ASTM-D 975-No 1-D and 2-D.
JIS KK 2204
Sulfur content: Complying with legal requirements in
each country. If sulfur content exceeds 0.5% by
weight, the oil change intervals must be changed,
please refer to the “Lubrication system” heading.
Extremely low sulfur content fuel (urban diesel in
Sweden and city diesel in Finland) can cause a loss
of up to 5% of power and an increase in fuel consumption of about 2–3 %.
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Maintenance
Fuel filter. Change
Cleanliness! No dirt must be allowed to get into the
fuel system.
WARNING! Fuel filters must be changed when
the engine is cold, to avoid the risk of fire due to
spilled fuel on hot surfaces.
Remove the filters. Wipe a film of oil on the gaskets
of the new filters. Screw the filters on by hand until
the gaskets just touch the mating surface. Then tighten a further half turn, no more. Vent the fuel system.
Hand old filters in to an authorized waste processing facility for destruction.
Start the engine and make sure that no leakage occurs.
Fuel system. Venting
The fuel system must be vented after a filter change,
if the fuel tank has been run dry, after a long-term
stoppage etc.
Use the hand pump, if fitted, to vent the fuel system.
In other cases, vent the system by operating the
starter motor.
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Maintenance
Electrical system
WARNING! Before any work is done on the electrical system, the engine must be stopped and the current
cut by switching off the main switch. Battery chargers or other auxiliary equipment installed on the engine
must be disconnected.
Fuses
No fuses or circuit breakers are supplied with the engine. Customers have to install the electrical system
on the side of the vehicle themselves.
Fuses cut the current if the electrical system is overloaded.
If the engine can not be started, or if the instrument
stop working during operation, a fuse or circuit breaker
can have tripped. Check and replace fuses or re-set
circuit breakers.
IMPORTANT! Always investigate the reason for
the overload!
Main switch
The main switch must never be disconnected before
the engine has been stopped. If the circuit between
the alternator and the battery is disconnected when
the engine is running, the alternator can be damaged.
IMPORTANT! Never disconnect the current with
the main switch when the engine is running.
Electrical connections
Check that electrical connections are dry, free from
oxide and that they are securely tightened. Spray
these connections as necessary with water-repellent
spray (Volvo Penta universal oil).
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Maintenance
Battery. Maintenance
WARNING! Fire and explosion hazard. Batteries
must never be exposed to open flames or
sparks.
WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and
explosion.
WARNING! Battery electrolyte is highly corrosive. Always protect your eyes, skin and clothes
when handling batteries. Always use protective
goggles and gloves. If acid comes into contact
with your skin, wash at once with soap and a lot
of water. If you get battery acid in your eyes,
flush at once with a lot of water, and get medical
assistance at once.
Connection and disconnection
When you connect batteries, first connect the + cable
(red) to the + pole on the battery. Then connect the cable (black) to the - pole on the battery
When you disconnect batteries, connect the - cable
(black) first, then the + cable (red).
Cleaning
Keep the batteries dry and clean. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Clean oxidation from the battery poles
and terminals, using a copper brush. Tighten the terminals securely and grease them with terminal grease
or Vaseline.
Filling
The electrolyte level should be 5-10 mm (0.2-0.4”)
above the cell plates in the battery. Top up with distilled water as necessary. After filling, the battery
should be charged for at least 30 minutes by running
the engine at fast idle. NOTE! Some maintenance-free
batteries have special instructions, which must be observed.
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Maintenance
Batteries, charging
WARNING! Explosion risk! Hydrogen is given off
when batteries are charged. This forms an explosive mixture with air. A short circuit, open flame
or spark could cause a violent explosion. Ventilate well.
WARNING! Battery electrolyte is highly corrosive. Protect your eyes, skin and clothes. Always use protective goggles and gloves. If acid
comes into contact with your skin, wash at once
with soap and a lot of water. If you get battery
acid in your eyes, flush at once with a lot of cold
water, and get medical assistance at once.
Charge batteries if they have become discharged. If
the engine is not used for a longer period of time, the
batteries should be fully charged, then possibly trickle
charged (please refer to the battery manufacturer’s
recommendations). Batteries are damaged by being
left discharged, and can also freeze and burst easier
in cold weather.
IMPORTANT! Observe the instruction manual for
the battery charger carefully. To avoid the risk of
electrochemical corrosion when an external
charger is connected, the battery cables should
be removed from the batteries before the charger
is connected.
During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if the
batteries are charged in an enclosed space.
WARNING! Always switch off the charge current
before undoing the charging clamps. Never confuse the positive (+) and negative (-) poles on the
batteries. This can cause serious arcing and can
cause an explosion.
Special instructions apply to so-called quick charging. Quick charging can shorten battery life, and
should therefore be avoided.
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Maintenance
Component location
1. Speed sensor, camshaft
2. Speed regulator / Actuator
3. Coolant temperature sensor
4. Charge pressure sensor, 3 pin*
5. Charge pressure sensor, 4 pin*
6. Connection to control unit
7. Fuel temperature sensor
8. Oil pressure sensor
* Only one type of sensor is used.
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Skötsel
Laying up
The engine must be laid up to prevent damage if it is not used for two months or more. It is important that this is
done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most
important points.
Before laying up for a long period of time, an authorized Volvo Penta workshop should check over the engine and
other equipment. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the
next start.
WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This
contains instructions for doing work in a safe and correct manner.
Conservation
●
Change engine oil and oil filter.
●
Change the fuel filter. Also change the primary fuel
filter, if fitted.
●
Warm the engine up.
●
Check that the coolant offers sufficient frost protection. Top up as necessary.
IMPORTANT! Anti-corrosion mixture does not
offer any protection against frost. If there is
any risk of frost, the system must be drained.
●
Drain any water and contamination from the fuel
tank. Fill the fuel tank completely, to avoid condensation.
●
Clean the outside of the engine. Do not use a power washer. Touch up paint damage with Volvo Penta original paint.
●
Disconnect the batteries. Clean and charge the
batteries. NOTE! A poorly charged battery can
freeze and burst.
●
Spray the components of the electrical system
with water-repellent spray.
Removing conservation
preparations
●
Check the oil level in the engine. Top up as necessary. If special conservation oil has been put in,
this must be changed together with the oil filter.
For the correct grade: Please refer to the “Maintenance, lubrication system” chapter:
●
Close/tighten drain taps/plugs.
●
Check the drive belts.
●
Check the condition of all rubber hoses, and retighten the hose clamps.
●
Check the coolant level and anti-freeze. Top up as
necessary.
●
Connect the fully charged batteries.
●
Start the engine. Check that there is no leakage of
oil, fuel, coolant or exhaust gas, and that all controls function normally.
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Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you can not solve by yourself.
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work.
Symptoms and possible causes
The diagnosis button lamp flashes.
Please refer to the “Diagnostic information” chapter.
Engine can not be stopped.
2, 4
Starter motor does not rotate
1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly
1, 2
Starter motor rotates normally but engine does not start
8, 9, 10, 11
Engine starts but stops again
8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle
9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly
10, 11, 27
High fuel consumption
12, 13, 15, 25
Black exhaust smoke
12, 13
Blue or white exhaust smoke
14, 15, 22
Too low lubrication oil pressure
16
Excessive coolant temperature
17, 18, 19, 20
Too low coolant temperature
20
No, or poor charge
2, 23
1. Flat batteries
10. Air in the fuel system
16. Too low oil level
2. Poor contact/open circuit in
cables
11. Water/contamination in fuel
17. Coolant level too low
12. Faulty injection pumps
18. Air in the coolant system
13. Insufficient air supply to engine:
– blocked air filter
– air leakage between turbocharger and engine inlet pipe.
– fouled compressor section in
turbocharger
– faulty turbocharger
– poor engine bay ventilation
19. Faulty circulation pump
14. Excessive coolant temperature
25. High back pressure in exhaust
system
3. Main switch turned off
4. Faulty ignition lock
5. Faulty main relay
6. Faulty starter motor relay
7. Faulty starter motor/solenoid
8. Lack of fuel:
– fuel taps closed
– fuel tank empty/wrong tank
connected
15. Too low coolant temperature
20. Defective thermostat
21. Blocked intercooler
22. Too high oil level
23. Alternator drive belt slips
24. Water entry into engine
26. Break in “Pot+” cable to pedal
9. Blocked fuel filter/pre-filter
(because of contamination, or
paraffin fraction separation in
fuel at low temperature).
27. Incorrectly set engine speed
regulator / actuator
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Diagnostic function
The diagnostic function monitors and checks that
the EDC 4 system functions normally.
Diagnostic function
Effect on engine
The diagnostic function has the following tasks:
The diagnostic function affects the engine in the following ways:
•
•
•
•
Discover and localize malfunctions.
Notify that malfunctions have been discovered.
Give advice in fault finding.
1. The diagnostic function has discovered a minor
malfunction which does not damage the engine.
Reaction: The engine is not affected. The diagnostic lamp lights up.
Protect the engine and ensure continued operation when serious malfunctions are discovered.
Malfunction message
2. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
the engine.
If the diagnostic function discovers a malfunction in
the EDC 4 system, this is notified via the CAN bus
or the diagnostic lamp lights up or starts to flash. At
the same time, the fault is stored in the control unit
memory. As soon as the fault has been attended to
and the ignition is turned off and on, the fault code
lamp goes out. Both rectified (passive) and un-rectified (active) faults are stored in the control unit and
can be read by an authorized workshop.
Reaction: The diagnostic lamp starts to flash. Engine is shut off.
Fault tracing guide
If the diagnostic button is depressed (for 1-3 seconds) and then released, a fault code is flashed out
from the diagnostic lamp. The fault code is found in
the fault code list, with information about the reason,
reaction and measures to be taken. Please refer to
the “Fault codes” chapter.
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Operation
During starting
Reading fault codes
When the ignition is turned on, the diagnostic lamp
lights up for two seconds, together with the warning
lamps for oil pressure and coolant. This is to check
the lamp function.
Fault codes can either be read via:
-
The VODIA tool (including the Penta EDC4 software). Please refer to the “VODIA User’s Guide”
for advice on use.
If the diagnostic lamp flashes after the two seconds,
this indicates a serious fault and the engine can not
be started. One or more fault codes can then be
flashed out.
-
Diagnostic lamp
-
CAN
If the diagnostic lamp is lit, there are one or more less
serious faults. One or more fault codes can then be
flashed out.
During operation
If the diagnostic lamp starts to flash during operation:
Diagnostic lamp
If the diagnostic lamp is illuminated or flashes, a fault
code can be read by pressing the diagnostic button
(for 1-3 seconds) and then releasing it. The diagnostic
lamp goes out, and a fault code is then flashed out.
The fault code consists of three groups of flashes,
separated by a pause of two seconds.
The first and third group consist of short flashes (0.4
s). The second group consists of long flashes (0.8 s).
1. Reduce engine speed to idling.
2. Press the diagnostic button (for 1-3 seconds).
3. Release the diagnostic button and make a note of
the diagnostic trouble code (DTC) that is flashed
out. Please refer to “Reading fault codes” below.
4. Look up the fault code in the fault code list and
take the necessary measures. Please refer to the
“Fault codes” chapter.
If the diagnostic lamp starts to flash, the engine will
be emergency stopped.
A fault code is obtained by counting the number of
flashes in each group.
Example:
(2 short) pause
(1 short) = Fault code 2.2.1
(2 long) pause
The fault code is stored and can be read as long as
the fault remains. You can find information about
cause, reaction and actions in the fault code list.
Please refer to “Fault codes”.
Read as follows:
IMPORTANT! In VE engines, there is a function in the system which makes it possible to
start the engine again and run it for about 25
seconds. This is so that the vehicle can be
moved from a railway level crossing etc.
1. Press the diagnostic button (for 1-3 seconds).
2. Release the diagnostic button and make a note of
the fault that is flashed out.
3. Repeat items 1-2. A new fault code is flashed out
if more are stored. Repeat until the first fault code
is repeated.
NOTE! When the first fault code is repeated, all fault
codes have been read out.
When all faults have been rectified:
1. Turn the ignition on and off.
2. Press the diagnostic button (for 1-3 seconds) to
check whether any faults remain.
3. If there are no active faults, the diagnostic lamp
will give two short flashes, in other cases the remaining non-rectified faults will be flashed out
again.
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Diagnostic function
Fault codes
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work.
Code 2.0.0
PID 91, Code 2.2.1 Accelerator pedal sensor
No faults
There are no active faults.
Reason: Faulty sensor, connector or cable.
Reaction: The engine goes into “limp home” mode.
PID 190, Code 2.1.1 Engine speed sensor,
camshaft
Reason: Faulty sensor, connector, cables or incorrect
distance to cam wheel. High frequency interference.
Action:
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
Reaction: Engine is shut off.
Action:
•
Check that the engine speed sensor is installed
with the correct distance to the camshaft.
•
Check the cables for the engine speed sensor for
breaks and short circuits.
•
Check the connector for poor contact.
•
Check engine speed sensor function. Change the
sensor as necessary.
PID 190, Code 2.1.4 Overspeed
Reason: The engine speed is or has been higher than
the permissible limit.
Reaction: Fuel injection ceases and the fault code
lamp lights up until the engine speed falls below the
permissible limit again.
Action:
•
Check the control rod for the injection pumps.
•
Check the actuator, replace it if necessary.
•
Check the cables for the actuator for breaks and
short circuits.
•
Check the number of teeth on the camshaft
wheel.
•
For VE engines, it may be necessary to check the
function of the “limp home” mode
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Fault codes
PID 102, Code 2.2.3 Charge pressure sensor
PID 174, Code 2.2.7 Fuel temperature sensor
Reason: Faulty sensor, connector or cable.
Reason: Faulty sensor, connector or cable.
Reaction: A fault code is generated.
Reaction: A fault code is generated.
Action:
Action:
•
Check the sensor cable for breaks and short circuits.
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
•
Check sensor function. Change the sensor as
necessary.
PID 100, Code 2.2.4 Oil pressure sensor
PID 100, Code 2.3.1 Warning, oil pressure
Reason: Faulty sensor, connector or cable.
Reason: Oil pressure below specified limit value (depends on engine speed).
Reaction: A fault code is generated.
Action:
•
•
Check the sensor cable for breaks and short circuits.
Check sensor function. Change the sensor as
necessary.
Reaction: A fault code is generated. The fault code
disappears when the oil pressure exceeds the recuperation value.
Action:
•
Check the oil level and oil pump.
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
•
Check the limit value for oil pressure warning.
PID 110, Code 2.2.5 Temperature sensor, coolant
Reason: Faulty sensor, connector or cable.
Reaction: A fault code is generated.
Action:
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
PID 110, Code 2.3.2 Warning, coolant temperature
Reason: Excessive coolant temperature
Reaction: A fault code is generated. The fault code
disappears when the coolant temperature falls below
the recuperation value.
Action:
•
Check the coolant.
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
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Fault codes
PID 111, Code 2.3.5 Warning, coolant level
PID 174, Code 2.3.7 Warning, fuel temperature
Reason: Coolant level too low
Reason: Excessive fuel temperature.
Reaction: A fault code is generated.
Reaction: A fault code is generated. The fault code
disappears when the fuel temperature falls below the
recuperation value.
Action:
•
Check the coolant level.
Action:
•
Check the sensor cable for breaks and short circuits.
•
Check the fuel.
•
Check sensor function (if installed).
Change the sensor as necessary.
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
NOTE! The engine is supplied without a coolant level
sensor.
PID 190, Code 2.3.6 Overspeed in limp home
mode
PID 100, Code 2.3.1 Emergency stop, oil pressure
Reason: Oil pressure below specified limit value.
Reason: When the limp home mode is activated and
the engine speed is or has been higher than the permissible limit value.
Reaction: Engine is emergency stopped.
Reaction: GE: Engine is shut off. A fault code is generated.
•
Check the oil level and oil pump.
•
VE: Fuel injection ceases when the control rod returns
to its home position and the fault code lamp lights up
until the engine speed falls below the permissible limit
again.
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
Action:
•
Check the limit value for engine shut-off due to oil
pressure.
Action:
•
Check the control rod for the injection pumps.
•
Check the actuator, replace it if necessary.
•
Check the cables for the actuator for breaks and
short circuits.
Reason: Excessive coolant temperature
•
Check the number of teeth on the camshaft
wheel.
Action:
•
For VE engines, it may be necessary to check the
function of the “limp home” mode
PID 110, Code 2.3.2 Emergency stop, coolant
temperature
Reaction: Engine is emergency stopped.
•
Check the coolant.
•
Check the sensor cable for breaks and short circuits.
•
Check sensor function. Change the sensor as
necessary.
•
Check the limit value for engine shut-off due to
coolant pressure.
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Fault codes
PID 111, Code 2.3.5 Emergency stop, coolant
level
SID 23, Code 2.5.1 Control rod position sensor,
difference
Reason: Low coolant level
Reaction: The engine is emergency stopped and can
not be re-started until the fault is rectified.
Reaction: A fault code is generated. The fault code
disappears when the difference between control rod
current value and nominal value falls below 10%.
Action:
•
Check coolant level.
•
Check the sensor cable for breaks and short circuits.
•
Reason: Injection pump/actuator has got stuck or is
not connected. Difference between control rod current
value and nominal value exceeds 10%.
Action:
Check sensor function (if installed).
Change the sensor as necessary.
NOTE! The engine is supplied without a coolant level
sensor.
•
Check the control rod for the injection pumps.
•
Check the actuator, control rod and injection
pumps. Change as necessary.
•
Check the cables for the actuator for breaks and
short circuits.
SID 24, Code 2.5.1 Control rod position sensor
Reason: Actuator not connected. Faulty value from
control rod position sensor in actuator.
SID 23, Code 2.5.2 Injection pump, auto
calibration
Reaction: Engine is emergency stopped. Actuator
can not be controlled.
Reason: Automatic actuator equalization is not possible. Faulty calibration.
Action:
•
Check the actuator. Change as necessary.
Reaction: The engine is emergency stopped and can
not be re-started until the fault is rectified. The regulator can not be activated.
•
Check the cables for the actuator for breaks and
short circuits.
Action:
SID 24, Code 2.5.1 Control rod position sensor,
reference
•
Check the actuator. Change as necessary.
•
Check the actuator cables.
•
Turn the ignition off and on, and check if the fault
code remains.
SID 231, Code 2.7.1 Communication fault, CAN
bus
Reason: Actuator not connected. Faulty value from
control rod position sensor in actuator.
Reaction: Engine is emergency stopped. Actuator
can not be controlled.
Reason: CAN controller for CAN bus is faulty.
Reaction: --
Action:
Action:
•
Check the actuator. Change as necessary.
•
Check the cables for the actuator for breaks and
short circuits.
•
Check the cables.
•
Check the control unit.
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Fault codes
SID 252, Code 2.8.1 Parameter programming
Reason: Memory fault
Reaction: The engine is emergency stopped and can
not be re-started until the fault is rectified.
Action:
Turn the ignition off and on, and check if the fault
code remains.
•
SID 240, Code 2.8.1 Cyclical program test
PID 158, Code 2.8.2 Reference voltage 2
Reason: Reference voltage for actuator exceeds permissible limit values.
Reaction: A fault code is generated. The fault code
disappears when the voltage returns to within the permissible limit values (5 V).
Action:
•
Check the voltage supplied.
•
Turn the ignition off and on, and check if the fault
code remains.
Reason: Memory fault
Reaction: The engine is emergency stopped and can
not be re-started until the fault is rectified.
Action:
Turn the ignition off and on, and check if the fault
code remains.
•
PID 158, Code 2.9.1 Control unit, voltage supply
PID 158, Code 2.8.2 Reference voltage 3
Reason: Reference voltage for actuator exceeds permissible limit values.
Reaction: A fault code is generated. The fault code
disappears when the voltage returns to within the permissible limit values (5 V).
Reason: Voltage supplied to actuator exceeds permissible limit values.
Action:
Reaction: A fault code is generated. The fault code
disappears when the voltage returns to within the permissible limit values.
•
Check the voltage supplied.
•
Turn the ignition off and on, and check if the fault
code remains.
Action:
Turn the ignition off and on, and check if the fault
code remains.
•
PID 158, Code 2.8.2 Reference voltage 1
Reason: Reference voltage for actuator exceeds permissible limit values.
Reaction: A fault code is generated. The fault code
disappears when the voltage returns to within the permissible limit values (5 V).
Action:
•
Check the voltage supplied.
•
Turn the ignition off and on, and check if the fault
code remains.
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PID 48, Code 2.9.2 Atmospheric pressure
SID 240, Code 2.10.1 Stack overflow
Reason: Air pressure is outside permissible values.
Reason: Internal calculation fault.
Reaction: A fault code is generated. The fault code
disappears when the pressure returns to normal. Monitoring function for air pressure is activated.
Reaction: The engine is emergency stopped and can
not be re-started until the fault is rectified.
Action:
Action:
•
Turn the ignition off and on, and check if the fault
code remains.
•
Turn the ignition off and on, and check if the fault
code remains.
SID 253, Code 2.10.1 Parameter fault
Reason: No data or incorrect data (fault only occurs
during parameter setting or reset).
Reaction: Engine can not be started.
Action:
•
Check parameter settings.
•
Turn the ignition off and on, and check if the fault
code remains.
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Felkoder
Technical data
General
Type designation .................................................... TD420VE
Direction of rotation (seen from flywheel) ............... Anti- clockwise
No. of cylinders ...................................................... 4
Cylinder bore mm (inch) ......................................... 101 (3.97”)
Stroke mm (inch) ................................................... 126 (4.96”)
Cylinder volume liter (inch 3 ) ................................... 4.04 (246.5)
No. of valves .......................................................... 8
Compression ratio:
EPA 1 ................................................................. 19:1
COM 2, EPA2 ..................................................... 19:1
Injection sequence ................................................. 1-3-4-2
Engine power kW (hp) ............................................ 75 (102)1)
Max torque Nm (lbf.ft) ............................................ 373 (275)
At engine speed rpm ........................................... 1800
Low idle rpm ........................................................... 800
Highest full load speed rpm .................................... 2000 – 2500 1)
Weight, dry (lb) ....................................................... 380 (838) 2)
Type designation .................................................... TAD520VE
Direction of rotation (seen from flywheel) ............... Anti- clockwise
No. of cylinders ...................................................... 4
Cylinder bore mm (inch) ......................................... 108 (4.25”)
Stroke mm (inch) ................................................... 130 (5.12”)
Cylinder volume liter (inch 3 ) ................................... 4.76 (290)
No. of valves .......................................................... 8
Compression ratio:
EPA 1 ................................................................. 18.1:1
COM2, EPA2 ...................................................... 19:1
Injection sequence ................................................. 1-3-4-2
Engine power kW (hp) ............................................ 118 (160))
Torque Nm (lbf.ft) ................................................... 552 (407)
At engine speed rpm ........................................... 1800
Low idle rpm ........................................................... 800 – 950
Highest full load speed rpm .................................... 2000 – 2300 1)
Weight, dry (lb) ....................................................... 432 (952) 2)
1)
See engine plate for specifications.
Weight according to DIN 70020-A
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
Including clutch and frame
2)
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TAD420VE
Anti- clockwise
4
101 (3.97”)
126 (4.96”)
4.04 (246.5)
8
TAD620VE
Anti- clockwise
6
98 (3.86”)
126 (4.96”)
5.7 (347.8)
12
19:1
19:1
1-3-4-2
103 (140)1)
477 (352)
1800
800
2000 – 2500 1)
380 (838) 2)
18.4:1
18.4:1
1-5-3-6-2-4
155 (211)1)
680 (501)
1800
800
2000 – 2500 1)
495 (1091) 2)
Technical data
Type designation .............................................
Direction of rotation, seen from flywheel: ........
No. of cylinders ...............................................
Cylinder bore mm (inch) ..................................
Stroke mm (inch) ............................................
Cylinder volume liter (inch 3 ) ............................
No. of valves ...................................................
Compression ratio:
EPA1 ...........................................................
COM2, EPA2 ...............................................
Injection sequence ..........................................
Engine power kW (hp) .....................................
Torque Nm (lbf.ft) ............................................
At engine speed rpm ....................................
Low idle rpm ....................................................
Highest full load speed rpm .............................
Weight, dry (lb) ................................................
TAD720VE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
TAD721VE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
TAD722VE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
18.4:1
19.0:1
1-5-3-6-2-4
174 (237)1)
817 (603)
1800
800 – 950
2000 – 2300 1)
572 (1261) 2)
18.4:1
19.0:1
1-5-3-6-2-4
195 (265)1)
897 (661)
1800
800 – 950
2000 – 2300 1)
572 (1261) 2)
—
19.0:1
1-5-3-6-2-4
200 (272)1)
981 (724)
1800
800 – 950
2100 – 2300 1)
680 (1496) 2
Type designation ..............................................
Direction of rotation (seen from flywheel)
No. of cylinders ................................................
Cylinder bore mm (inch) ...................................
Stroke mm (inch) .............................................
Cylinder volume liter (inch 3 ) .............................
No. of valves ....................................................
Compression ratio:
EPA1 ............................................................
EPA2 ............................................................
EU2 ..............................................................
Injection sequence ...........................................
Engine power:
At 1500 rpm kW (hp) .....................................
At 1800 rpm kW (hp) .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Low idle rpm .....................................................
Highest full load speed rpm ..............................
Weight, dry (lb) .................................................
Gross weight, dry (lb)
TD520GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
TAD530GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
TAD531GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
1-3-4-2
18.0:1
1-3-4-2
18.0:1
1-3-4-2
1-3-4-2
85 (116)1)
89 (121)1)
541 (399)
1500
472 (348)
1800
800 – 950
1500/1800 1)
550 (1213) 2)
580 (1279) 2)
89 (139)1)
95 (150)1)
567 (479)
1500
504 (430)
1800
800 – 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
102 (139)1)
110 (150)1)
649 (479)
1500
584 (430)
1800
800 – 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
129 (139)1)
136 (150)1)
821 (479)
1500
722 (430)
1800
800 – 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
1)
2)
3)
4)
17.5:1
17.5:1
TAD532GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
18.0:1
See engine plate for specifications.
Weight according to DIN 70020-A
Extra weight TAD530/31/32GE SAE 2 (1800 rpm) 36 kg (80 lb)
Including clutch and frame
47
119/209
Technical data
Type designation ................................
Direction of rotation (seen from flywheel)
No. of cylinders ..................................
Cylinder bore mm (inch) ......................
Stroke mm (inch) ................................
Cylinder volume liter (inch 3 ) ...............
No. of valves ......................................
Compression ratio:
EPA1 ...............................................
EPA2 ...............................................
EU2 .................................................
Injection sequence .............................
Engine power:
At 1500 rpm kW (hp) .......................
At 1800 rpm kW (hp) .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Low idle rpm .......................................
Highest full load speed rpm ................
Weight, dry (lb) ...................................
Gross weight, dry (lb)
1)
2)
3)
4)
TD720GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
17.1:1
17.1:1
TAD730GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
1-5-3-6-2-4
17.1:1
18.0:1
1-5-3-6-2-4
128 (174)1)
134 (182)1)
815 (601)
1500
711 (524)
1800
800 – 950
1500/1800 1)
750 (1653) 2)
790 (1742) 2)
129 (208)1)
136 (222)1)
821 (718)
1500
722 (638)
1800
800 – 950
1500/1800 1)
760 (1674) 2)
804 (1773) 2)
See engine plate for specifications.
Weight according to DIN 70020-A
Extra weight TAD530/31/32GE SAE 2 (1800 rpm) 36 kg (80 lb)
Including clutch and frame
48
120/209
TAD731GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
TAD732GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7,15 (436)
12
TAD733GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7,15 (436)
12
17.1:1
17.1:1
18,0:1
18,0:1
1-5-3-6-2-4
1-5-3-6-2-4
1-5-3-6-2-4
153 (208)1)
163 (222)1)
974 (718)
1500
865 (638)
1800
800 – 950
1500/1800 1)
760 (1674) 2)
804 (1773) 2)
201 (273)1)
225 (306)1)
1280 (944)
1500
1193 (880)
1800
800 – 950
1500/18001)
785 (1731)2)
826 (1821)2)
201 (273)1)
225 (306)1)
1280 (944)
1500
1193 (880)
1800
800 – 950
1500/18001)
785 (1731)2)
826 (1821)2)
Technical data
Lubrication system
Oil
Change volume, including filter change,
TD420VE/TAD420VE: .............................................
TD520GE/TAD530/531GE/TAD520VE,TAD532GE:
TAD620VE: .............................................................
TAD720VE/TAD721VE/TD720GE/TAD730/731GE:
TAD722VE: .............................................................
TAD732GE/TAD733GE: ..........................................
10 liter (2.64 US gal)
13 liter (3.43 US gal)
16 liter (4.22 US gal)
20 liter (5,28 US gal)
23 liter (6.07 US gal)
34 liter (8.97 US gal)
Oil pressure with engine oil at operating temperature (min 120°C)
At rated engine speed:
TD520GE//TD720GE: .............................................
400 kPa (58 psi)
TD420VE/TAD420VE/TAD620VE/TAD520VE/
TAD720VE/TAD721VE/TAD722VE: ........................
450 kPa (65 psi)
TAD530/531GE, TAD532GE: ..................................
450-480 kPa
TAD730/731GE/TAD732/733GE: ............................
480-520 kPa
Idle (800 rpm), min:
TD420VE/TAD420VE/TAD620VE/TAD520VE/
TAD720VE/TAD732GE/TAD721VE/TAD733GE/
TAD722VE, TD720GE/TAD730/731GE: ..................
TD520GE/TAD530/531GE/TD720GE/
TAD532GE: ............................................................
80 kPa (11.6 psi)
90 kPa (13 psi)
Automatic stop at pressure less than:
TD420VE/TAD420VE/TAD620VE/
TAD520VE/TAD720VE/TAD721VE/TAD722VE: .....
TD520GE/TAD530/531GE/TD720GE/TAD730/731GE/
TAD732GE/TAD733GE/: .........................................
50kPa (7.2 psi)
200kPa (29 psi)
Oil grade ................................................................ Please refer to the specification under “Maintenance.
Viscosity ................................................................ Please refer to the specification under “Maintenance.
Oil filter, full flow filter:
Quantity .................................................................
(tighten ½ - ¾ turn after it just touches)
1
Lubrication oil pump
Type ...................................................................... Gear driven oil pump
49
121/209
Technical data
Fuel system
Injection sequence
TD420VE/TAD420VE/TD520GE/
TAD530/531GE/TAD520VE,TAD532GE: ................
TAD620VE/TD720GE/TAD730/731GE/
TAD720VE/TAD732GE/TAD721VE/TAD733GE
TAD722VE: .............................................................
Feed pump
Supply pressure: ........................................................
Supply pressure after fuel filter at
1500 rpm: Min .........................................................
By-pass valve
Opening pressure .......................................................
1-3-4-2
1-5-3-6-2-4
0.5 MPa (72.5 psi)
0.28 MPa (40.6 psi)
360–440 kPa (52.2–63.8 psi)
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold requirements)
ASTM D 975 No 1-D and 2-D.
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an
increase in fuel consumption of about 2-3%.
50
122/209
Technical data
Cooling system
Type ..........................................................................
Pressurized, sealed
Pressure cap, max. opening pressure:
TD420VE/TAD420VE/TAD620VE/
TD520GE/TAD530/531GE/
TAD520VE/TAD720VE/TAD732GE
TAD721VE/TAD733GE/TAD722VE: .......................
90 kPa (13 psi)1)
TD720GE/TAD730/731GE, TAD532GE: .................
60 kPa (8.7 psi)
1)
Refers to VE engines which are not equipped with a pressure valve at the factory.
Volume (engine)
TD420VE/TAD420VE: .............................................
TAD620VE: .............................................................
TD520GE/TAD530/531GE/TAD520VE: ...................
TAD720VE/TD720GE/TAD730/731GE/
TAD732GE/TAD721VE/TAD733GE/TAD722VE: .....
Volume (engine + radiator and hoses)
TD520GE: ...............................................................
TAD530/531GE: ......................................................
TD720GE ................................................................
TAD730/731GE, TAD532GE ...................................
TAD732GE/TAD733GE ...........................................
Thermostat
Quantity and type .......................................................
Opening temperature
TD420VE/TAD420VE/TAD620VE/
TD520GE/TAD530/531GE/
TD720GE/TAD730/731GE, TAD532GE: .................
TAD520VE/TAD720VE/TAD732GE/
TAD721VE/TAD733GE/TAD722VE: .......................
Fully open at
TD420VE/TAD420VE/TAD620VE/
TD520GE/TAD530/531GE/
TD720GE/TAD730/731GE, TAD532GE: .................
TAD520VE/TAD720VE/TAD732GE/
TAD721VE/TAD733GE/TAD722VE: .......................
4,7 liter (1.24 US gal)
6 liter (1.58 US gal)
7,2 liter (1.9 US gal)
9,8 liter (2.59 US gal)
17,5 liter (4.62 US gal)
19,7 liter (5.2 US gal)
22 liter (5.8 US gal)
23,8 liter (6.3 US gal)
27,3 liter (7.2 US gal)
1 piston thermostat
83° C (181° F)
87° C (189° F)
95° C (203° F)
102° C (216° F)
Coolant filter
Quantity .................................................................. 1
Electrical system
System voltage ..........................................................
24 V (standard), 12 V (option)
51
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Notes
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✂
Yes please,
I would like an operator’s manual in English at no charge.
Orders can also be placed
via the Internet:
http://www.volvopenta.com/
manual/coupon
Publication number: 7745131
42200/615001/155099900192
Post or fax this coupon to:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Name
Address
Country
Please note that this offer is valid for 12 months from the date of delivery
of the engine, after this it is subject to availability.
✂
Ja,
ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Die Bestellung kann auch
über das Internet erfolgen:
http://www.volvopenta.com/
manual/coupon
Publikationsnummer: 7745203
42200/615001/155099900192
Schicken Sie den Coupon
per Post oder als Fax an:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Schweden
Fax: +46 31 545 772
Name
Anschrift
Land
Bitte beachten Sie, dass das Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Motors gilt, danach nur noch bis zum Aufbrauchen des Lagerbestandes.
✂
Oui merci,
Vous pouvez également passer la commande par Internet:
http://www.volvopenta.com/
manual/coupon
42200/615001/155099900192
Envoyez ou faxez le bon de
commande à:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Suède
Fax: +46 31 545 772
Je souhaite recevoir un manuel d’instructions gratuit en français.
Numéro de publication: 7745204
Nom
Adresse
Pays
Noter que l’offre est valable 12 mois à partir de la date de livraison du
moteur, puis seulement dans la mesure des stocks disponibles.
127/209
✂
Sí gracias,
deseo recibir gratuitamente un libro de instrucciones en español.
El pedido puede hacerse
también por internet:
http://www.volvopenta.com/
manual/coupon
Número de publicación: 7745205
42200/615001/155099900192
Franquear o enviar fax a:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Suecia
Fax: +46 31 545 772
Nombre
Dirección
País
Observe que la oferta es válida durante 12 meses a partir de la fecha de entrega
del motor. A partir de la fecha de finalización de la oferta, la misma es válida siempre que haya existencias.
✂
Sì, grazie,
desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
L’ordinazione può essere fatta anche su Internet:
http://www.volvopenta.com/
manual/coupon
Public. No.: 7745206
42200/615001/155099900192
Spedire il tagliando per posta o
per fax a:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Svezia
Fax: +46 31 545 772
Nome e Cognome
Indirizzo
Paese
Notare che la validità dell’offerta è garantita solo per 12 mesi dalla consegna del
motore, dopodiché si procederà fino ad esaurimento scorte.
✂
Ja tack,
Posta eller faxa kupongen till:
Dokument & Distribution center
Ordermottagningen
ARU 2, Avd. 64620
SE-405 08 Göteborg
Sverige
Fax: +46 31 545 772
Beställningen kan även göras
via internet:
http://www.volvopenta.com/
manual/coupon
Publikationsnummer: 7745201
Namn
Adress
Land
Observera att erbjudandet gäller i 12 månader från motorns
leveransdatum, därefter endast i mån av tillgång.
128/209
42200/615001/155099900192
jag vill kostnadsfritt ha en instruktionsbok på svenska.
✂
Ja graag,
Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
U kunt ook bestellen via
internet:
http://www.volvopenta.com/
manual/coupon
Publicatienummer: 7745208
42200/615001/155099900192
Stuur of fax de coupon naar:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Zweden
Fax: +46 31 545 772
Naam
Adres
Land
Denk eraan dat de aanbieding geldt tot 12 maanden na levering van de
motor, daarna nog slechts indien beschikbaar.
✂
Kyllä kiitos,
haluan suomenkielisen ohjekirjan veloituksetta.
Tilauksen voi tehdä myös
Internetissä:
http://www.volvopenta.com/
manual/coupon
Julkaisunumero: 7745207
42200/615001/155099900192
Postita tai faksaa kuponki
osoitteella:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Ruotsi
Fax: +46 31 545 772
Nimi
Osoite
Maa
Ota huomioon, että tarjous on voimassa 1 vuoden ajan
moottorin luovutuspäivämäärästä, sen jälkeen vain
tuotteen saatavuuden perusteella.
✂
Sim, obrigado(a)!
Envie o talão pelo correio ou
um fax para:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Suécia
Fax: +46 31 545 772
A encomenda também pode
ser feita através da Internet:
http://www.volvopenta.com/
manual/coupon
Número de publicação: 7745209
Nome
Endereço
País
Notar que a oferta é válida por um período de 12 meses a partir da data de entrega do motor. Depois desse período, a oferta é válida consoante a disponibilidade.
129/209
42200/615001/155099900192
Gostaria de receber gratuitamente um manual de instruções em português.
✂
Íáé,
Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò
êáìéÜ ÷ñÝùóç.
Ìðïñåßôå åðßóçò íá äþóåôå
ôçí ðáñáããåëßá óáò ìÝóù ôïõ
Internet, óôç äéåýèõíóç:
http://www.volvopenta.com/
manual/coupon
Áñéèìüò Ýêäïóçò: 7745210
¼íïìá
Äéåýèõíóç
×þñá
Ðáñáêáëïýìå óçìåéþóôå üôé áõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá 12 ìÞíåò áðü ôçí
çìåñïìçíßá ðáñÜäïóçò ôçò ìç÷áíÞò. ÌåôÜ èá åßíáé èÝìá äéáèåóéìüôçôáò.
Äà, ïîæàëóéñòà,
Öåíòð ïîäãîòîâêè
äîêóìåíòàöèè è
ðàñïðîñòðàíåíèÿ
ß áû õîòåë èìåòü áåñïëàòíîå ðóêîâîäñòâî îïåðàòîðà íà ðóññêîì ÿçûêå.
Íîìåð èçäàíèÿ: 7745212
Èìÿ
Àäðåñ
Îòäåë îáðàáîòêè çàêàçîâ
ARU2, Îòä. 64620
SE-405 08 Ãåòåáîðã
Øâåöèÿ
Ôàêñ: +46 31 545 772
Çàêàçû òàêæå ìîæíî
ðàçìåùàòü ÷åðåç Èíòåðíåò:
http://www.volvopenta.com/
manual/coupon
✂
42200/615001/155099900192
Îòïðàâüòå ýòîò òàëîí
ïî÷òîé èëè ôàêñîì íà
èìÿ:
42200/615001/155099900192
Ôá÷õäñïìÞóôå áõôü ôï
êïõðüíé
óôçí
ðáñáêÜôù
äéåýèõíóç
Þ
óôåßëôå
ôï
ìå öáî óôïí ðáñáêÜôù
áñéèìü
öáî:
Document & Distribution Center
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Ñòðàíà
Ê Âàøåìó ñâåäåíèþ, ýòî ïðåäëîæåíèå äåéñòâèòåëüíî â òå÷åíèå 12
ìåñÿöåâ îò äàòû ïîñòàâêè äâèãàòåëÿ; â äàëüíåéøåì îíî çàâèñèò îò
íàëè÷èÿ.
130/209
131/209
132/209
7745131 English 06-2007
9.2.
Appendix B - Alternator user and maintenance manual
133/209
134/209
User guide and maintenance manual
LEROY SOMER
Alternator
LSA46.2 L6 - L9
LSA46.2 M3 - M5
46-2 SHUNT & AREP & PMG
3856 h
01/03/2012
33522061001_8_1
135/209
136/209
3856 en - 2011.01 / h
371
364
367
49
48
124
120
122
177
198
41
466
15
n
ive
be g
o
t
s
i
ual d user
man
n
This to the e
322
325
320
30
321
1
31
37
347
323
33
34
4
343
100
78
28
LSA 46.2 - 4 POLES
ALTERNATORS
Installation and maintenance
137/209
70
349
79
91
90
36
LEROY-SOMER
Installation and maintenance
3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
This manual concerns the alternator which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.
SAFETY MEASURES
WARNING SYMBOLS
Before using your machine for the first time,
it is important to read the whole of this
installation and maintenance manual.
We wish to draw your attention to the
following 2 safety measures which must be
complied with:
All necessary operations and interventions
on this machine must be performed by a
qualified technician.
a) During operation, do not allow anyone
to stand in front of the air outlet guards,
in case anything is ejected from them.
Our technical support service will be pleased
to provide any additional information you
may require.
b) Do not allow children younger than 14
to go near the air outlet guards.
The various operations described in this
manual are accompanied by recommendations or symbols to alert the user to the
potential risk of accidents. It is vital that you
understand and take notice of the different
warning symbols used.
A set of self-adhesive stickers depicting the
various warning symbols is included with
this maintenance manual. They should be
positioned as shown in the drawing below
once the machine has been fully installed.
Warning symbol for an operation capable
of damaging or destroying the machine
or surrounding equipment.
WARNING
The alternators must not be put into
service until the machines in which they
are to be incorporated have been
declared compliant with Directives EC
and plus any other directives that may be
applicable.
Warning symbol for general danger to
personnel.
Note: LEROY-SOMER reserves the right to
modify the characteristics of its products at
any time in order to incorporate the latest
technological developments. The information contained in this document may
therefore be changed without notice.
WARNING
Warning symbol for electrical danger to
personnel.
Copyright 2005 : MOTEURS LEROYSOMER
This document is the property of:
MOTEURS LEROY SOMER.
It may not be reproduced in any form without
prior authorization.
All brands and models have been registered
and patents applied for.
2
138/209
LEROY-SOMER
Installation and maintenance
3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
CONTENTS
1 - RECEIPT.............................................................................................................................4
1.1 - Standards and safety measures....................................................................................4
1.2 - Inspection......................................................................................................................4
1.3 - Identification.................................................................................................................. 4
1.4 - Storage.........................................................................................................................4
1.5 - Applications................................................................................................................... 4
1.6 - Contraindications to use................................................................................................4
2 - TECHNICAL CHARACTERISTICS.....................................................................................5
2.1 - Electrical characteristics................................................................................................5
2.2 - Mechanical characteristics............................................................................................5
3 - INSTALLATION................................................................................................................... 6
3.1 - Assembly.......................................................................................................................6
3.2 - Checks prior to first use.................................................................................................7
3.3 - Terminal connection diagrams.......................................................................................7
3.4 - Commissioning........................................................................................................... 10
3.5 - Setting up.................................................................................................................... 10
4 - SERVICING - MAINTENANCE.......................................................................................... 11
4.1 - Safety measures......................................................................................................... 11
4.2 - Routine maintenance.................................................................................................. 11
4.3 - Fault detection............................................................................................................. 11
4.4 - Mechanical defects.....................................................................................................12
4.5 - Electrical faults............................................................................................................ 12
4.6 - Dismantling, reassembly.............................................................................................14
4.7 - Installation and maintenance of the PMG....................................................................16
4.8 - Table of characteristics................................................................................................17
5 - SPARE PARTS.................................................................................................................. 18
5.1 - First maintenance parts...............................................................................................18
5.2 - Technical support service............................................................................................18
5.3 - Accessories................................................................................................................. 18
5.4 - Exploded views, parts list and tightening torque..........................................................19
EC declaration of incorporation..........................................................................................22
3
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ALTERNATORS
1 - RECEIPT
1.1 - Standards and safety
measures
• C : excitation system
(C : AREP / J : SHUNT or PMG / E :
COMPOUND)
• 6/4 : winding number / number of poles.
1.2 - Inspection
1.3.1 - Nameplate
So that you can identify your machine
quickly and accurately, we suggest you
write its specifications on the nameplate
below.
On receipt of your alternator, check that it
has not suffered any damage in transit. If
there are obvious signs of knocks, contact
the transporter (you may be able to claim
on their insurance) and after a visual
check, turn the machine by hand to detect
any malfunction.
1.3 - Identification
The alternator is identified by means of a
nameplate fixed on the machine (see
drawing).
Make sure that the nameplate on the
machine conforms to your order.
The machine name is defined according to
various criteria, for example :
LSA 46.2 M5 C6/4 • LSA : name used in the PARTNER range
M : Marine
C : Cogeneration
T : Telecommunications
• 46.2 : machine type
• M5 : model
1.4 - Storage
Prior to commissioning, machines should
be stored :
- Away from humidity (< 90%); after a long
period of storage, check the machine
insulation (section 3.2.1). To prevent the
bearings from becoming marked, do not
store in an environment with significant
vibration.
1.5 - Application
These alternators are mainly designed to
produce electricity in the context of
applications involving the use of
generators.
1.6 - Contraindications to use
Use of the machine is restricted to operating
conditions (environment, speed, voltage,
power, etc) compatible with the characteristics indicated on the nameplate.
ALTERNATEURS
LSA
Date
N 5700 125897 A15
Hz
Min-1/R.P.M. 1500 Protection
Cos Ø /P.F. 0,8 Cl. ther. / Th.class
Régulateur/A.V.R.
R 438 B
Altit.
m Masse / Weight
Rlt AV/D.E bearing
6302 2 RS C3
Rlt AR/N.D.E bearing 6303 2 RS C3
Graisse / Grease
45g / 3600 h
Valeurs excit / Excit. values
en charge / full load
à vide
/ at no load
166631
C
US
ALTERNATORS
PUISSANCE / RATING
Tension
Voltage
V
Ph.
Connex.
kVA
Continue
Continuous
kW
40C
A
kVA
Secours
Std by
kW
27C
A
(*) Tension maxi. / maximum voltage
Conforme à C.E.I 60034-1. According to I.E.C 60034-1.
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Made in France - 1 024 959/a
Our alternators comply with most
international standards.
See the EC Declaration of Incorporation on
the last page.
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ALTERNATORS
2 - TECHNICAL CHARACTERISTICS
1.1 - Electrical characteristics
The LSA 46.2 alternator is a machine
without sliprings or revolving armature
brushes, wound as “2/3 pitch”, 6 or 12wire, with class H insulation and a field
excitation system available in either
SHUNT, AREP or «PMG» version (see
diagrams and AVR manuals).
2.1.1 - Electrical options
- Stator temperature detection sensors
- Bearing sensors (PTC, PT100, etc)
- Space heater
Interference suppression conforms to
standard EN 55011, group 1, class B
(Europe).
SHUNT SYSTEM
2.2 - Mechanical characteristics
- Steel frame
- Cast iron end shields
- Protected ball bearings, greased for life
- Mounting arrangements:
IM 1201 (MD 35) foot and flange mounted,
single-bearing with SAE coupling disc.
IM 1001 (B 34) double-bearing with SAE
flange and standard cylindrical shaft
extension.
- Drip-proof machine, self-cooled
- Degree of protection: IP 23
2.1.1 - Mechanical options
- Air inlet filter
- Regreasable ball bearings
- IP 44 protection
STATOR : 12-wire (marking T1 to T 12)
MAIN FIELD
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
Varistor
EXCITER
5+
Armature
6-
Field
R 250
AREP SYSTEM
Power supply / Detection
STATOR : 6 or 12-wire (marking T1 to T 12)
MAIN FIELD
Aux. windings
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
Varistor
EXCITER
5+
Armature
6-
Field
R 450
PMG SYSTEM
STATOR : 6 or 12-wire (marking T1 to T12)
MAIN FIELD
Varistor
EXCITER
5+
Armature
Voltage reference
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
PMG
6-
Field
R 450
Voltage reference
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ALTERNATORS
3 - INSTALLATION
Personnel undertaking the various
operations indicated in this section must
wear personal protective equipment
appropriate for mechanical and electrical hazards.
3.1 - Assembly
3.1.2 - Coupling
3.1.2.1 - Single-bearing alternator
Before coupling the machines, check that
they are compatible by:
- undertaking a torsional analysis of the
transmission,
- checking the dimensions of the flywheel
and its housing, the flange, coupling discs
and offset.
WARNING
All mechanical handling operations
must be undertaken using suitable
equipment and the machine must be
horizontal. Check how much the machine
weighs (see 4.8.3.) before choosing the
lifting tool.
3.1.1 - Handling
The generously-sized lifting rings are for
handling the alternator alone. They must not
be used to lift the genset. The choice of
lifting hooks or handles should be determined
by the shape of these rings. Choose a lifting
system which respects the integrity and the
environment of the alternators.
When coupling the alternator to the
prime mover, do not use the fan to turn
the alternator or rotor.
The holes of the coupling discs should
be aligned with the flywheel holes by
cranking the engine.
Make sure the alternator is securely
bedded in position during coupling.
Check that there is lateral play on the
crankshaft.
3.1.2.2 - Double-bearing alternator
- Semi-flexible coupling
Careful alignment of the machines is
recommended, checking that the lack of
concentricity and parallelism of both parts
of the coupling do not exceed 0.1 mm.
This alternator has been balanced with a
1/2 key.
3.1.3 - Location
The room where the alternator is placed
must be ventilated to ensure that the
ambient temperature cannot exceed the
data on the nameplate.
3.2 - Checks prior to first use
3.2.1 - Electrical checks
During this operation, do not allow
anyone to stand under the load.
Under no circumstances should an
alternator, new or otherwise, be operated
if the insulation is less than 1 megohm
for the stator and 100,000 ohms for the
other windings.
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ALTERNATORS
There are 2 possible methods for restoring
the above minimum values.
a) Dry out the machine for 24 hours in a
drying oven at a temperature of 110 °C
(without the regulator).
b) Blow hot air into the air intake, having
made sure that the machine is rotating with
the exciter field disconnected.
Note : Prolonged standstill: In order to avoid
these problems, we recommend the use of
space heaters, as well as turning over the
machine from time to time. Space heaters
are only really effective if they are working
continuously while the machine is stopped.
- the standard direction of rotation is clockwise as seen from the shaft end (phase
rotation in order 1 - 2 - 3).
For anti-clockwise rotation, swap 2 and 3.
- the winding connection corresponds to the
site operating voltage (see section 3.3).
3.3 - Terminal connection diagrams
To modify the connection, change the
position of the stator cables on the terminals.
The winding code is specified on the
nameplate.
3.3.1 - Terminal connection: 12 wire
The connection accessories are detailed in
section 5.3.3.
WARNING
Ensure that the alternator has the
degree of protection matching the
defined environmental conditions.
3.2.2 - Mechanical checks
Before starting the machine for the first time,
check that:
- all fixing bolts and screws are tight.
- the cooling air is drawn in freely.
- the protective grilles and housing are correctly in place.
Connection codes
A
T1
3-phase
Voltage L.L
L1(U)
Winding
T7
T4
T12
N
T10
T5
T9
T3
T8
T1
D
190 - 240
7
220
-
8
-
190 - 208
3-phase
T7
T12
T9
T6
T3
L3(W)
N
T10
T11
50 Hz
60 Hz
6
380 - 415
380 - 480
7
440
-
8
-
380 - 416
Winding
T4
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 450 voltage detection :
0 => (T3) / 380 V => (T2)
T5
T8
T2
L2(V)
T12
T11
T10
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
L2(V)
L1(U)
Factory connection
60 Hz
190 - 208
T6
L3(W)
50 Hz
6
T2
T11
Any intervention on the alternator
terminals during reconnection or checks
should be performed with the machine
stopped.
9
500
T9
T6
T5
T4
T8
T7
T3
T11
T10
T6
T5
T4
L2(V)
T1
L1(U)
N
NDE
T12
L3(W)
T2
T9
T8
T7
NDE
T3
L3(W)
T2
L2(V)
T1
L1(U)
N
600
Winding 9 : R 450 voltage detection + transformer (See specific diagram AREP or SHUNT)
In case of reconnection, ensure that AVR voltage detection is correct !
The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*).
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Connection codes
Voltage L.L
50 Hz
60 Hz
6
220 - 240
220 - 240
7
240 - 254
-
8
-
220 - 240
Winding
FF
1 phase
T2
T3
T11
T5
T4
T1
L
T12
T8
T6
T9
T7
T10
Voltage LM = 1/2 voltage LL
T12
1 phase
or
3-phase
T1
T9
T4
T7
T6
T3
L3(W)
L
T10
T8
T11
T5
M
50 Hz
60 Hz
6
220 - 240
220 - 240
7
240 - 254
-
8
-
220 - 240
Winding
L1(U)
F
T2
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
L2(V)
L
Voltage LM = 1/2 voltage LL
G
1 PH
T6
T12
T7
M
T1
T4
T3
T9
T10
L
T2
T5
T11
Voltage LM = 1/2 voltage LL
L
T8
Winding
50 Hz
6
220 - 240
T3
T9
T6
T11
T2
T5
T8
T10
T4
T1
T7
7
250 - 260
-
8
200
220 - 240
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
In case of reconnection, ensure that AVR voltage detection is correct !
L1(U)
M
NDE
T12
T6
T3
T9
11
T8 T2
T5
T10
T1
T4
L2(V)
*
( )
L3(W)
T7
L2(V)
L1(U)
M
NDE
Operating phases L2 (V), L3 (W) single phase
60 Hz
220 - 240
*
( )
T12
R 250 voltage detection :
0 => (T4) / 110 V => (T1)
R 450 voltage detection :
0 => (T10) / 220 V => (T1)
L
M
Factory connection
*
( )
T12
T3
T6
T9
T2
T11 T5
T8
L3(W)
L2(V)
T10 T4
T7
NDE
T1
M
The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*).
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ALTERNATORS
3.3.2 - Terminal connection: 6 wire (not possible with the R 250)
Connection codes
Voltage L.L
L1(U)
D
T1
3-phase
N
T4
Factory connection
Winding
50 Hz
60 Hz
6S
7S
8S
380 - 415
380 - 480
440
-
-
380 - 416
T6
T3
-
Winding
50 Hz
60 Hz
6S
220 - 240
220 - 277
7S
240 - 254
9S
L1(U)
1 phase or 3-phase
T1
T3
8S
T4
T2
T5
T2
T6
T1
L2(V)
L1(U)
N
600
L2(V)
L3(W)
L3(W)
T4
L3(W)
NDE
Winding 9 : R 450 voltage detection
+ transformer (See specific diagram)
T2
T6
T3
R 450 voltage detection :
0 => (T3) / 380 V => (T2)
T5
F
T5
-
-
T3
T4
220 - 240
T6
L3(W)
T2
L2(V)
T1
L1(U)
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
L2(V)
*
( )
T5
NDE
Operating phases : L2 (V), L3 (W) single phase
In case of reconnection, ensure that the AVR voltage detection is correct !
The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*).
3.3.3 - Option connection diagram
R 791 T interference suppression kit (standard for CE marking)
Connections
Black
Black
Black
Blue
White
A
D
F
T1
T2
T3
N
T1
T2
T3
N
T1
T2
T3
Remote voltage potentiometer
ST4
Voltage adjustment
via remote potentiometer
Current transformer connection (optional)
Coupling D - PH 1
In - Secondary 1 A
Neutral
link
Coupling D & A- PH 1
In - Secondary 1A (coupl. D)
T4
P2
P1
6-wire
Neutral
link
Anti condensation heater
101
T10
P2
P1
12-wire
Thermistor (PTC) temperature
103
250W - 220 V
102
104
Ph1
130 C blue wire
Ph2
150C black wire
Ph3
180 C red/white wire
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ALTERNATORS
3.3.4 - Connection checks
3.4 - Commissioning
Electrical installations must comply with
the current legislation in force in the
country of use.
Check that:
- The residual circuit-breaker conforms to
legislation on protection of personnel, in
force in the country of use, and has been
correctly installed on the alternator power
output as close as possible to the alternator.
(In this case, disconnect the wire of the
interference suppression module linking the
neutral).
- Any protection devices in place have not
been tripped.
- If there is an external AVR, the connections
between the alternator and the cabinet are
made in accordance with the connection
diagram.
- There is no short-circuit phase-phase or
phase-neutral between the alternator output
terminals and the generator set control
cabinet (part of the circuit not protected by
circuitbreakers or relays in the cabinet).
- The machine should be connected with the
busbar separating the terminals as shown in
the terminal connection diagram.
The machine can only be started up and
used if the installation is in accordance
with the regulations and instructions
defined in this manual.
The machine is tested and set up at the
factory. When first used with no load, make
sure that the drive speed is correct and
stable (see the nameplate). With the
regreasable bearing option, we recommend
greasing the bearings at the time of
commissioning (see 4.2.3).
On application of the load, the machine
should achieve its rated speed and voltage;
however, in the event of abnormal operation,
the machine setting can be altered (follow
the adjustment procedure in section 3.5). If
the machine still operates incorrectly, the
cause of the malfunction must be located
(see section 4.4).
3.5 - Setting up
The various adjustments during tests
must be made by a qualified engineer.
Ensure that the drive speed specified on
the nameplate is reached before
commencing adjustment.
After operational testing, replace all
access panels or covers.
The AVR is used to make any adjustments
to the machine.
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4 - SERVICING - MAINTENANCE
4.1 - Safety measures
Servicing or troubleshooting must be
carried out strictly in accordance with
instructions so as to avoid the risk of
accidents and to maintain the machine in
its original state.
All such operations performed on the
alternator should be undertaken by
personnel trained in the commissioning,
servicing and maintenance of electrical
and mechanical components, who must
wear personal protective equipment
appropriate for mechanical and electrical
hazards.
Before any intervention on the machine,
ensure that it cannot be started by a manual
or automatic system and that you have
understood the operating principles of the
system.
4.2 - Routine maintenance
4.2.1 - Checks after start-up
After approximately 20 hours of operation,
check that all fixing screws on the machine
are still tight, plus the general state of the
machine and the various electrical
connections in the installation.
4.2.2 - Bearings
As standard, the alternator is fitted with
permanently greased bearings. As an
option, they may be regreasable. It is
advisable to lubricate the alternator during
operation. Time intervals and quantity of
grease are given in the table below.
NDE/DE bearing
Quantity of grease
Regreasing interval
6316 C3 6315 C3
33 g
30 g
4000 H 4500 H
Lubrication intervals are given for grease
type: LITHIUM - standard - NLGI 3.
In the factory, the grease used for lubrication
is: ESSO - Unirex N3.
Before using another grease, check for
compatibility with the original one. Monitor
the temperature rise in the bearings (see
section 4.4).
4.2.3 - Electrical servicing
Commercially-available volatile degreasing
agents can be used.
WARNING
Do not use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline
products.
These operations must be performed at a
cleaning station, equipped with a
vacuum system that collects and flushes
out the products used.
The insulating components and the
impregnation system are not at risk of
damage from solvents. Avoid letting the
cleaning product run into the slots.
Apply the product with a brush, sponging
frequently to avoid accumulation in the
housing. Dry the winding with a dry cloth. Let
any traces evaporate before reassembling
the machine.
4.2.4 - Mechanical servicing
WARNING
Cleaning the machine using water or a
highpressure washer is strictly prohibited. Any problems arising from such
treatment are not covered by our
warranty.
Degreasing: Use a brush and detergent
(suitable for paintwork).
Dusting: Use an air gun.
If the machine is fitted with air inlet and outlet
filters, the maintenance personnel should
clean them routinely at regular intervals. In
the case of dry dust, the filter can be cleaned
using compressed air and/or replaced if it is
clogged.
After cleaning the alternator, it is essential to
check the winding insulation (see sections
3.2 and 4.8).
4.3 - Fault detection
If, when commissioned, the alternator does
not work normally, the source of the
malfunction must be identified (see sections
4.4 and 4.5).
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4.4 - Mechanical defects
Fault
Action
- If the bearing has turned blue or if the grease has turned black, change the bearing
Excessive temperature rise in one or
both bearings (bearing temperature more - Bearing not fully locked (abnormal play in the bearing cage)
Bearing
- Check the end shield alignment (flange not properly fitted)
than 80 °C) with or without abnormal
bearing noise
- Air flow (intake-outlet) partially clogged or hot air is being recycled from the alternator
Excessive temperature rise in the
or engine
Abnormal
alternator housing (more than 40° C
- Alternator operating at too high a voltage (> 105% of Un on load)
temperature
above the ambient temperature)
- Alternator overloaded
- Misalignment (coupling)
Excessive vibration
- Defective mounting or play in coupling
- Rotor balancing fault (Engine - Alternator)
Vibration
Excessive vibration and humming noise - Phase imbalance
coming from the machine
- Stator short-circuit
- System short-circuit
- Mis-paralleling
Possible consequences:
Alternator damaged by a significant
- Broken or damaged coupling
Abnormal
impact, followed by humming and
- Broken or bent shaft extension
noise
vibration
- Shifting and short-circuit of revolving field winding
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes, AVR, surge suppressor
4.5 - Electrical faults
Fault
Action
Connect a new battery
No voltage of 4 to 12 volts to
at no load on terminals E- and E+,
respecting the polarity,
start-up
for 2 to 3 seconds
Voltage too
low
Check the drive speed
Effect
The alternator builds up and its
voltage is still correct when
the battery is removed
The alternator builds up but its voltage
does not reach the rated value when
the battery is removed
The alternator builds up but its
voltage disappears when the battery
is removed
Correct speed
Speed too low
Voltage too
high
Adjust AVR voltage
potentiometer
Voltage
oscillations
Adjust the
AVR stability
potentiometer
Voltage
correct at no
load and too
low when on
load
Run at no load and
check the voltage
between E+ and E- on
the AVR
Voltage
disappears
during
operation
Check the AVR, the
surge suppressor,
The voltage does not return to the
the rotating diodes, and
rated value
replace any defective
components
Adjustment ineffective
Check/Cause
- Lack of residual magnetism
- Check the connection of the voltage reference to the AVR
- Faulty diodes
- Armature short-circuit
- Faulty AVR
- Field windings open circuit (check winding)
- Revolving field coil open circuit (check the resistance)
Check the AVR connections (AVR may be faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Revolving field coil short-circuited
- Check the resistance
Increase the drive speed (do not touch the AVR voltage pot. (P2)
before running at the correct speed)
Faulty AVR
- Check the speed: possibility of cyclic irregularity
If no effect: try normal or fast stability - Loose connections
- Faulty AVR
modes (ST2)
- Speed too low when on load (or AVR LAM set too high)
Voltage between E+ and E- (DC)
- Check the speed (or AVR LAM set too high)
SHUNT / AREP / PMG < 10V
- Faulty rotating diodes
Voltage between E+ and E- Short-circuit in the revolving field coil. Check the resistance.
SHUNT / AREP / PMG > 15V
- Faulty exciter armature. Check the resistance.
- Exciter winding open circuit
- Faulty exciter armature
- Faulty AVR
- Revolving field coil open circuit or short-circuited
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4.5.1 - Checking the winding
You can check the winding insulation by
performing a high voltage test. In this case,
you must disconnect all AVR wires.
Assembly A: Connect a 12 V battery in
series with a rheostat of approximately
50 ohms - 300 W and a diode on both exciter
field wires (5+) and (6-).
ASSEMBLY A
WARNING
Diode 1A
Damage caused to the AVR in such
conditions is not covered by our
warranty.
C
C
C
A
A
A
~
+
C
~
~
~
C
~
-
C
~
Cathode
+
-
A
C
+
-
A
C
+
Anode
A
-
C
A A A
4.5.3 - Checking the windings and
rotating diodes using separate
excitation
12V battery
Assembly B: Connect a “Variac” variable
power supply and a diode bridge on both
exciter field wires (5+) and (6-).
Both these systems should have
characteristics which are compatible with
the field excitation power of the machine
(see the nameplate).
3) Run the unit at its rated speed.
4) Gradually increase the exciter field
current by adjusting the rheostat or the
variac and measure the output voltages on
L1 - L2 - L3, checking the excitation voltage
and current at no load (see the machine
nameplate or ask for the factory test report).
When the output voltage is at its rated value
and balanced within 1% for the rated
excitation level, the machine is in good
working order. The fault therefore comes
from the AVR or its associated wiring (ie.
sensing, auxiliary windings).
ASSEMBLY B
20
Diode 1A
10
90
100
0
Variac
5+
+
60
30
50
80
1) Stop the unit, disconnect and isolate the
AVR wires.
2) There are two ways of creating an
assembly with separate excitation.
40
6 - Exciter field
70
During this procedure, make sure that
the alternator is disconnected from any
external load and inspect the terminal
box to check that the connections are
fully tightened.
Rh. 50Ω -300W
+
-
4.5.2 - Checking the diode bridge
A diode in good working order should allow
the current to flow only in the anode-tocathode direction.
6 - Exciter field 5 +
AC
220V
-
DC
12V
13
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LSA 46.2 - 4 POLES
ALTERNATORS
4.6 - Dismantling, reassembly
(see sections 5.4.1. & 5.4.2.)
WARNING
During the warranty period, this
operation should only be carried out in
an LEROY-SOMER approved workshop
or in our factory, otherwise the warranty
may be invalidated.
Whilst being handled, the machine
should remain horizontal (rotor not
locked in position). Check how much the
machine weighs (see 4.8.3) before
choosing the lifting method.
4.6.1 - Tools required
To fully dismantle the machine, we
recommend using the tools listed below:
- 1 ratchet spanner + extension
- 1 torque wrench
- 1 set of flat spanners: 8 mm, 10 mm, 18 mm
- 1 socket set: 8, 10, 13, 16, 18, 21, 24, 30 mm
- 1 socket with male ferrule: 5 mm
- 1 puller
4.6.2 -Screw tightening torque
See section 5.4.
4.6.3 - Access to diodes
- Open the air intake grille (51).
- Disconnect the diodes.
- Check the 6 diodes, change the diode
bridges if necessary.
4.6.4 - Access to connections and the
regulation system
Access directly by removing the top of the
cover (48) or the AVR access door (466).
4.6.5 - Replacing the NDE bearing
- Remove the box lid (48) and the NDE panel
(365) and remove the 2 screws from the part
(122).
- Disconnect the stator outputs (T1 to T12).
- Disconnect the auxiliary winding wires
AREP (X1,X2,Z1,Z2).
- Disconnect the exciter wires (5+,6-).
- Remove the air inlet louvre (51).
If using a single-bearing or double-bearing
machine with the regreasable bearing
option:
- Remove the bearing (78) thrust screws
(72).
- Remove all 4 screws (37).
- Remove the shield (36).
- Take out the antifriction bearing (70) using
a puller with a central screw (see drawing
below).
- Fit the new antifriction bearing onto the
shaft after heating it by induction to
approximately 80 °C.
- Mount the new preloading (wavy) washer
(79) + the new “O” ring seal (349) in the
shield (36) and coat the bearing seat with
adhesive paste (see After Sales Service).
If using a single-bearing or double-bearing
machine with the regreasable bearing
option:
- Screw a threaded rod into the thrust
bearing (78).
- Refit the end shield on the machine using
a dowel and nut in the shaft extension (see
drawing).
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LSA 46.2 - 4 POLES
ALTERNATORS
- Slide the threaded rod into the shield hole
to make it easier to assemble (see basic
diagram).
4
78 36
Threaded rod
Dowel
Nut
- Slide the threaded rod into the shield hole
to make it easier to assemble (see basic
diagram).
- Tighten the bottom thrust bearing screws
(78), remove the threaded rod and fit the
other screws.
- Tighten the 6 shield screws (31).
- Refit the air outlet grille (33).
4.6.7 - Dismantling the rotor assembly
- Remove the NDE shield (36) as described
in section 4.6.5.
- Remove the DE shield (30) as described
in section 4.6.6 if it is a double-bearing
machine.
- Support the DE rotor (4) with a strap or with
a support constructed in accordance with
the following drawing.
- Move the strap as the rotor moves in order
to distribute the weight over it.
Rotor
NDE shield
- Fit the thrust bearing screws (78), remove
the threaded rod, fit the other screw and
tighten up the assembly.
- Tighten the 4 bearing screws (37).
- Reconnect wires.
- Fit the 2 support screws (122).
- Fit the air inlet louvre (51).
- Replace the cover.
WARNING
WARNING
When dismantling the shields, you will
need to change the antifriction bearings,
the “O” ring seal, the preloading (wavy)
washer and adhesive paste.
4.6.6 - Replacing the DE bearing
- Remove the air outlet grille (33).
- Remove the 6 screws (31) from the DE
shield and the 3 screws (62) from the inner
bearing retainer.
- Remove the shield (30).
- Take out the ball bearing (60) using a puller
with a central screw (see section 4.6.5).
- Fit the new bearing, after heating it by
induction to approximately 80 °C.
- Screw a threaded rod into the thrust
bearing (68).
- Refit the shield (30) on the machine.
When dismantling the rotor involves
changing parts or rewinding, the rotor
must be rebalanced.
4.6.8 - Reassembling the machine
- Mount the rotor (4) in the stator (1) (see
drawing above) taking care not to knock the
windings.
15
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LSA 46.2 - 4 POLES
ALTERNATORS
If using a single-bearing or double-bearing
machine with the regreasable bearing
option:
- Mount the new preloading (wavy) washer
(79) + the new “O” ring seal (349) in the
shield (36).
- Screw a threaded rod into the thrust
bearing (78).
- Refit the shield (36) on the machine using
a dowel and nut in the shaft extension (see
diagram).
- Slide the threaded rod into the shield hole
to make it easier to assemble (see diagram).
- Fit the thrust bearing screws (78), remove
the threaded rod, fit the other screw and
tighten up the assembly.
- Tighten the 4 bearing screws (37).
- Reconnect exciter wires E+, E-.
- Finish reassembling the cover.
- Refit the flange (30) on the stator (1).
- Tighten the screws (31).
If using a double-bearing machine:
- Mount the new preloading (wavy) washer
(79) + the new “O” ring seal (349) in the
shield (36).
- Refit the shield (36) on the machine using
a dowel and nut in the shaft extension (see
diagram).
- Tighten the 4 shield screws (37).
- Reconnect exciter wires E+, E-.
- Finish reassembling the cover.
- Screw a threaded rod into the thrust
bearing (68).
- Refit the shield (30) on the machine.
- Slide the threaded rod into the shield hole
to make it easier to assemble (see basic
diagram).
- Fit the thrust bearing screws (68), remove
the threaded rod, fit the other screw and
tighten up the assembly.
- Tighten the 6 shield screws (31).
- Refit the air outlet grille (33).
- Check that the machine assembly is
correctly mounted and that all screws are
tightened.
To replace, follow the instructions in reverse
order.
51
418
417
4.7 - Installation and maintenance of
the PMG
For the LSA 46.2, the PMG reference is:
PMG 2.
See the PMG manual ref : 4211.
4.6.9 - Dismantling and reassembly of
the filters
- Remove the grille (417) then take out the
filter (418). Change the filter if necessary;
please refer to section 4.2.5 for cleaning the
filter.
16
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LSA 46.2 - 4 POLES
ALTERNATORS
4.8 - Table of characteristics
Table of average values
Alternator - 4 poles - 50 Hz - Standard
winding No. 6.
(400V for the excitation values)
The voltage and current values are given for
no-load operation and operation at rated
load with separate field excitation.
All values are given to within ± 10% and may
be changed without prior notification (for
exact values, consult the test report).
4.8.1 - LSA46.2 average values
Resistances at 20 °C (Ω)
0.022
0.0182
0.0148
0.012
0.0085
0.23
0.24
0.264
0.295
0.343
8.8
8.8
8.8
8.8
10
LSA 46.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2
50 Hz
70 V
10 V
60 Hz
85 V
12 V
4.8.3 - Table of weights
(values given for information only)
LSA 46.2 Total weight (kg)
LSA 46.2 Stator L/N Rotor Field Armature
M3
M5
L6
L9
VL12
4.8.2 - Voltage of auxiliary windings at
no load
0.035
0.035
0.035
0.035
0.037
Rotor (kg)
M3
600
250
M5
700
260
L6
800
290
L9
850
320
VL12
1000
380
Resistance of AREP auxiliary windings
at 20 °C (Ω)
LSA 46.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2
M3
M5
L6
L9
VL12
0.24
0.215
0.185
0.19
0.17
0.4
0.36
0.36
0.32
0.32
After operational testing, it is essential to
replace all access panels or covers.
Field excitation current i exc (A)
Symbols : “i exc”: excitation current of the
exciter field
LSA 46.2
No load
At rated load
M3
M5
L6
L9
VL12
1.1
1.1
1.1
1.2
1.1
4
3.8
4.1
4
3.5
For 60 Hz machines, the “i exc” values are
approximately 5 to 10 % lower.
17
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LSA 46.2 - 4 POLES
ALTERNATORS
5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an
option.
They contain the following items:
Emergency kit SHUNT
AVR R 250
Diode bridge assembly
Surge suppressor
ALT 472 KS 001
-
Emergency kit AREP
AVR R 450
Diode bridge assembly
Surge suppressor
ALT 461 KS 001
-
Single-bearing kit
Non drive end bearing
«O» ring
Preloading (wavy) washer
ALT 471 KB 002
-
Double-bearing kit
Non drive end bearing
Drive end bearing
«O» ring
Preloading (wavy) washer
ALT 471 KB 001
-
5.2 - Technical support service
Our technical support service will be pleased
to provide any additional information you
may require.
When ordering spare parts, you should
indicate the complete machine type, its
serial number and the information given on
the nameplate.
In the event of failure to comply with this
advice, the manufacturer cannot be held
responsible for any damage.
5.3 - Accessories
5.3.1 - Space heater for use when
stopped
The space heater must run as soon as the
alternator stops. It is installed at the rear of
the machine. Its standard power is 250W
with 220V or 250W with 110V on request.
Warning: the power supply is present
when the machine has stopped.
5.3.2 - Temperature sensors with
thermistors (PTC)
These are thermistor triplets with a positive
temperature coefficient installed in the
stator winding (1 per phase). There can be a
maximum of 2 triplets in the winding (at 2
levels: warning and trip) and 1 or 2
thermistors in the shields.
These sensors must be linked to adapted
sensing relays (supplied optionally).
Cold resistance of cold thermistor sensors:
100 to 250 Ω per sensor.
5.3.3 - Connection accessories
- 6-wire machines : coupling (F)
- 12-wire machines : coupling (A), (F .F), (F)
Address your enquiry to your usual contact.
Part numbers should be identified from the
exploded views and their description from
the parts list.
Our extensive network of service centres
can dispatch the necessary parts without
delay.
After operational testing, it is essential to
replace all access panels or covers.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacturer spare parts.
18
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3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
5.4 - Exploded view, parts list and tightening torque
323
37
31
1
322
325
320
15
30
321
466
41
198
177
371
364
33
48
34
49
4
28
347
343
100
78
70
349
79
367
91
124
90
120
36
122
51
365
72
21
71
53
5.4.1 - LSA 46.2 single-bearing
19
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Installation and maintenance
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3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
34
37
62
30
33
284
60
22
1
31
466
41
198
177
371
364
68
48
15
49
4
28
343
347
100
70
349
79
367
91
124
90
120
36
122
51
365
71
53
21
5.4.2 - LSA 46.2 double-bearing
20
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LEROY-SOMER
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3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
Screw Torque
Screw Torque
Ref. Qty
Description
Ø
N.m
Ø
N.m
1
1
Stator assembly
90
1 Exciter field
4
1
Rotor assembly
91
4 Fixing screws
M6
10
15
1
Fan
100 1 Exciter armature
21
1
Lifting ring
120 1 Terminal plate support
22
1
Shaft extension key
122 1 Plate support
28
1
Earth terminal
M10
20
124 1 Terminal plate
M12
35
30
1
Drive end shield
177 2 AVR support bracket
Voltage regulator
31 6 or 4 Fixing screws
M14
80(*) 198 1
(AVR)
33
1
Protective grille
284 1 Circlips
34
2
Fixing screws
M6
5
320 1 Coupling sleeve
36
1
Exciter end shield
321 1 Sleeve key
37
4
Fixing screws
M12
50
322 3 Coupling disc
41
1
Cover front panel
323 6 Fixing screw
M16
230
48
1
Cover top panel
325 - Spacer shim
Diode bridge
49
Cover screws
M6
5
343 1
M6
4
assembly
Protection varistor
51
1
Air intake grille
347 1
(+ PCB)
53
1
Plug
349 1 “O” ring
60
1
Drive end bearing
364 1 AVR support
62 3 or 4 Fixing screws
M8
20
365 1 Cover rear panel
68
1
Inner bearing retainer
367 2 Side panel
70
1
Non drive end bearing
371 4 Damper
71
1
Cover
416 1 Filter
72
2
Fixing screws
M8
20
417 1 Filter support
78
1
Inner bearing retainer
466 2 AVR inspection door
Preloading (wavy)
79
1
washer
Ref.
Qty
Description
(*) 80 N.m in M / 190 N.m in L, VL
21
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LEROY-SOMER
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LSA 46.2 - 4 POLES
ALTERNATORS
Electric Power Generation Division
Declaration of CE compliance and incorporation
This Declaration applies to the generators designed to be incorporated into machines complying with the
Machinery Directive Nr 2006/42/CE dated 17 May 2006.
MOTEURS LEROY-SOMER
Boulevard Marcellin Leroy
16015 ANGOULEME
France
MLS HOLICE STLO.SRO
SLADKOVSKEHO 43
772 04 OLOMOUC
Czech Republic
MOTEURS LEROY-SOMER
1, rue de la Burelle
Boite Postale 1517
45800 St Jean de Braye
France
Declares hereby that the electric generators of the types LSA 36 – 37– 40 – 42.2 – 43.2 – 44.2 – 46.2 – 47.2 –
49.1 – 50.2 – 51.2, as well as their derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf,
comply with the following International Standards and Directive :
- EN and IEC 60034 -1 and 60034 -5
- ISO 8528 – 3 “ Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets ”
- Low Voltage Directive Nr 2006/95/CE dated 12 December 2006.
Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Directives :
- Machinery Directive Nr 2006/42/CE dated 17 May 2006
- EMC Directive Nr 2004/108/CE dated 15 December 2004, as intrinsic levels of emissions and
immunity are concerned
WARNING :
The here above mentioned generators should not be commissioned until the corresponding Gen-Sets have
been declared in compliance with the Directives Nr 2006/42/CE et 2004/108/CE, as well as with the other
relevant Directives.
Leroy Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant information on
the generator.
Technical Managers
P Betge – J.Begué
4152 en – 2010.11 / d
22
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3856 en - 2011.01/ h
LSA 46.2 - 4 POLES
ALTERNATORS
23
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LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
338 567 258 RCS ANGOULÊME
www.leroy-somer.com
160/209
4067 en - 2009.05 / b
STATOR : 12 wires (marking T1 to T12)
MAIN FIELD
T1 T7
T2
T8
T3
T4
T5
T11
T6
Varistor
SHUNT SYSTEM
5+
Induced
6-
Field
T10
75 mm
R 250
P1
Voltage
ST4
Stability
Option
R250
A.V.R.
Installation and maintenance
161/209
KNEE
65Hz
LAM OFF
KNEE
57Hz
LAM OFF
External potentiometrer
for voltage adjusting
9
LAM OFF
SPECIAL
8
7
50Hz
o
901
6
1
23
P2
KNEE
47.5Hz
78
Slow fuse
250V 8 A
5
4
60Hz
LAM
OFF
2
3
13%
25%
OFF
13%
25%
LAM
FREQ. & L.A.M. CONFIG.
F1
456
n to
give
to be
s
i
l
er
ua
man e end us
This
th
STAB VOLT
140 mm
110 0V E+ E-
4 x holes Ø 5.8 x
50 x 115 mm
Frequency selector 50 H
/ 60 Hz for U/F fonction
and LAM adjustement
LEROY-SOMER
Installation and maintenance
R250
4067 en - 2009.05 / b
A.V.R.
This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your A.V.R., you can
look forward to many years of trouble-free operation.
SAFETY MEASURES
WARNING
Before using your machine for the first time,
it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions
on this machine must be performed by a
qualified technician.
Warning symbol for an operation capable
of damaging or destroying the machine
or surrounding equipment.
Our technical support service will be pleased
to provide any additional information you
may require.
The various operations described in this
manual
are
accompanied
by
recommendations or symbols to alert the
user to potential risks of accidents. It is vital
that you understand and take notice of the
following warning symbols.
Warning symbol for general danger to
personnel.
Warning symbol for electrical danger to
personnel.
Note : LEROY-SOMER reserves the right to
modify the characteristics of its products at
any time in order to incorporate the latest
technological developments.
The information contained in this document
may therefore be changed without notice.
2
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LEROY-SOMER
Installation and maintenance
R250
4067 en - 2009.05 / b
A.V.R.
SUMMARY
1 - SUPPLY...............................................................................................................................4
1.1 - SHUNT excitation system.............................................................................................4
2 - R250 A.V.R..........................................................................................................................5
2.1 - Characteristics.............................................................................................................. 5
2.2 - U/F fonction and LAM....................................................................................................5
2.3 - R250 A.V.R. option........................................................................................................ 5
2.4 - LAM Characteristics .....................................................................................................6
2.5 - Typical effects of the LAM..............................................................................................7
3 - INSTALLATION - COMMISIONING....................................................................................8
3.1 - Electrical checks on the AVR.........................................................................................8
3.2 - Settings.........................................................................................................................8
3.3 - Electrical faults.............................................................................................................. 9
4 - SPARE PARTS.................................................................................................................. 10
4.1 - Designation.................................................................................................................10
4.2 - Technical support service............................................................................................10
Any maintenance or breakdown operations on the A.V.R. are to be done by personnel
trained on commisioning, servicing and maintenance for the electrical and mechanical
elements.
The R250 is an IP00 product. It must be installed inside a unit so that this unit’s cover can provide
IP20 minimum total protection (it must only be installed on LS alternators in the appropriate
location so that when viewed externally, it has a higher degree of protection than IP20).
Copyright 2005: MOTEURS LEROY-SOMER
This document is the property of:
MOTEURS LEROY SOMER.
It may not be reproduced in any form without prior authorization
All brands and models have been registered and patents applied for.
163/209
3
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Installation and maintenance
4067 en - 2009.05 / b
R250
A.V.R.
1 - SUPPLY
1.1 - SHUNT excitation system
The regulator controls the excitation current
according to the alternator’s output voltage.
With a very simple conception, the SHUNT
excitation alternator does not have a short
circuit capacity.
The SHUNT excitation alternator is autoexcited with a R 250 voltage regulator.
STATOR : 12 wires (marking T1 to T12)
MAIN FIELD
T1
T7
T2
T8
T3
T9
T4
T10
T5
T11
T6
T12
Varistor
SHUNT SYSTEM
5+
Induced
6-
Field
75 mm
R 250
Voltage
ST4
9
LAM OFF
SPECIAL
KNEE
65Hz
LAM OFF
KNEE
57Hz
LAM OFF
8
7
50Hz
o
901
6
5
4
60Hz
Option
External potentiometrer
for voltage adjusting
4
1
23
P2
Stability
KNEE
47.5Hz
78
P1
456
Slow fuse
250V 8 A
164/209
LAM
OFF
2
3
13%
25%
OFF
13%
25%
LAM
FREQ. & L.A.M. CONFIG.
F1
STAB VOLT
140 mm
110 0V E+ E-
4 x holes Ø 5.8 x
50 x 115 mm
Frequency selector 50 Hz
/ 60 Hz for U/F fonction
and LAM adjustement
Installation and maintenance
LEROY-SOMER
R250
4067 en - 2009.05 / b
A.V.R.
2 - R250 A.V.R.
2.1 - Characteristics
The threshhold position and LAM fonction
settings are done with the jumper.
-Storage: -55°C; +85°C
-Operation: -40°C; +70°C
-Voltage regulation: around ± 0,5 %.
-Supply range/voltage detection 85 to 139 V
(50/60Hz).
-Rapid response time (500 ms) for a
transient voltage variation amplitude of
± 20 %.
-Voltage setting P1.
-Stability setting P2.
-Power supply protected by 8 A fuse,
replacement product: Ferraz-Shawmut
T084013T fast-blow fuse, 8 A FA 250 V,
breaking capacity 30 kA.
The threshold position (50 Hz - 60 Hz) to
action the U/F fonction as well as the LAM
setting type is selected using the
potentionmeter.
50Hz
KNEE
LAM OFF
KNEE
57Hz
LAM OFF
7
78
65Hz
901
6
5
OFF
13%
2
3
4
60Hz
1: threshold at 48 Hz with LAM 13% for
impacts between 40 and 70% of the rated
load.
2: threshold at 48 Hz with LAM 25% for
impacts > 70% of the rated load.
Operating at 60 Hz: (U/F gradient)
3: threshold at 58 Hz without LAM for impacts
between 30 and 40% of the rated load.
5: threshold at 58Hz with LAM 25% for
impacts > 70% of the rated load.
Specific operating
6: threshold at 57Hz without LAM for speed
variations at a steady state > 2 Hz
LAM
1
23
KNEE
8
456
SPECIAL
o
9
LAM OFF
0: threshold at 48 Hz without LAM for impacts
between 30 and 40% of the rated load.
4: threshold at 58Hz with LAM 13% for
impacts 40 and 70% of the rated load.
2.2 - U/F Fonction and LAM
47.5Hz
Operating at 50 Hz: (U/F gradient)
7: threshold at 65Hz without LAM for variable
speed and tractelec / gearlec (U/F
gradient).
25%
OFF
13%
8: special: the factory setting 48Hz 2U/F
gradient ; a special programme is possible
on request. This programme must be
specified before ordering, during the project
study.
25%
LAM
WARNING: The jumper settings must
correspond to the rated operating
frequency (see the nameplate on the
alternator).
Risk of destruction for the alternator.
165/209
9: threshold at 47.5 Hz without LAM for
speed variations at a steady state > 2 Hz.
For hydraulic applications, it is advisable to
select:
- position 0 for 50 Hz
- position 3 for 60 Hz
5
LEROY-SOMER
Installation and maintenance
4067 en - 2009.05 / b
R250
A.V.R.
2.3 - R250 A.V.R. option
Potentiometer for voltage setting, 1000 W /
0,5 W min: setting range ± 5 %.
- Remove the ST4 jumper.
It is advised to use the “LAM” at 25% for load
impacts > at 70% of the genset rated power.
Voltage
Voltage
UN
0,85 UN
For wiring up the external potentiometer;
the “earth” wires must be isolated as
well as the potentiometer terminals
(wires at the same voltage as the power).
2.4 - LAM characteristics (Load
Acceptance Module)
2.4.1 - Voltage drop
The LAM system is integrated in the A.V.R.
It is active as standard. It can be adjusted to
13% or 25%.
- Role of the «LAM» (Load Adjustment
Module):
On application of a load, the rotation speed
of the generator set decreases. When it
passes below the preset frequency
threshold, the LAM causes the voltage to
drop by approximately 13% or 25% and
consequently the amount of active load
applied is reduced by approximately 25% to
50%, until the speed reaches its rated value
again.
Hence the “LAM” can be used either to
reduce the speed variation (frequency) and
its duration for a given applied load, or to
increase the applied load possible for one
speed variation (turbo-charged engines).
To avoid voltage oscillations, the trip
threshold for the “LAM” function should be
set approximately 2 Hz below the lowest
frequency in steady state.
6
0
U/f
LAM
48 or 58 Hz
ST3
fC
50 or 60 Hz
fN
2.4.2 - Gradual voltage return function
During load impacts, the function helps the
genset to return to its rated speed faster
thanks to a gradual increase in voltage
according to the following principles:
- if the speed drops between 46 Hz and 50 Hz,
the rated voltage follows a fast gradient as it
is restored.
- if the speed drops below 46 Hz, since the
engine needs more help, the voltage follows
a slow gradient as it returns to the reference
value.
U
Drop N < 46 Hz
0
166/209
Drop N > 46 Hz
Time
Installation and maintenance
LEROY-SOMER
R250
4067 en - 2009.05 / b
A.V.R.
2.5 - Typical effects of the LAM with
a diesel engine or without a LAM
(U/F only)
2.5.1 - Voltage
Transient voltage drop
UN
0,9
(U/f)
without LAM
with
LAM
0,8
1s
0
Time
2s
3s
2.5.2 - Frequency
Max speed drop
fN
with
LAM
0,9
without
LAM
0,8
1s
0
2s
Time
3s
2.5.3 - Power
Load on
shaft (kW)
LAM
0
Load variation
Shedding due to "LAM"
1s
2s
Time
3s
167/209
7
LEROY-SOMER
Installation and maintenance
R250
4067 en - 2009.05 / b
A.V.R.
3 - INSTALLATION COMMISSIONING
3.1 - Electrical checks on the AVR
- Check that all connections have been
made properly as shown in the attached
wiring diagram.
- Check that the position of the jumper
corresponds to the operating frequency.
- Check whether the ST4 jumper or the
remote adjustment potentiometer have
been connected.
3.2.2 - Special type of use
WARNING
Excitation circuit E+, E- must not be left
open when the machine is running:
A.V.R. damage will occur.
3.2.2.1 - R250 field weakening (SHUNT)
The different settings made during the
trial are to be done by qualified personnel.
Respecting the load speed specified on
the nameplate is vital in order to start a
settings procedure. After operational
testing, replace all access panels or
covers.
The only possible settings on the
machine are to be done with the A.V.R.
110
0V
E+
E-
3.2 - Settings
The exciter is switched off by disconnecting
the A.V.R. power supply (1 wire - 0 or 110V).
Contact rating: 16A - 250V AC
Do not reclose the power supply until the
voltage has reached a value ≤15% of the
rated voltage (approximately 5 seconds
after opening)
3.2.2.2 - R250 field forcing
(400V - 10A)
t
Initial potentiometer positions
- voltage setting potentiometer P1 for the
A.V.R.: full left
- remote voltage setting potentiometer: in
the middle.
Operate the alternator at its rated speed: if
the voltage does not rise it is necessary to
re-magnatise the magnetic circuit.
- slowly adjust the voltage potentiometer of
the A.V.R. P1 until the output voltage reaches
its rated value.
- Stability setting with P2.
110
0V
E+
E-
3.2.1 - R250 settings (SHUNT system)
Diode
-
Battery (B Volt)
Excitation Inducer
The battery must be isolated from the
mass.
Exciter field may be at line potential.
8
+
168/209
LEROY-SOMER
Installation and maintenance
R250
4067 en - 2009.05 / b
A.V.R.
3.3 - Electrical faults
Fault
Action
Connect a new battery
No voltage at of 4 to 12 volts to
no load on
terminals E- and E+
start-up
respecting the polarity
for 2 to 3 seconds
Voltage too
low
Effect
- Lack of residual magnetism
The alternator starts up but its
voltage disappears when the
battery is removed
- Faulty A.V.R.
- Exciter field short-circuited
- Short-circuit in the main field. Check the
resistance
The alternator starts up but its
voltage does not reach the rated
value when the battery is
removed.
Correct speed
Check the drive speed
Speed too low
Voltage too
high
Adjust A.V.R.
potentiometer
Voltage
oscillations
Adjust A.V.R. stability
potentiometer
Voltage
correct at no
load and too
low when on
load (*)
Run at no load and
check the voltage
between E+ and E- on
the A.V.R.
Check/cause
The alternator starts up and its
voltage is still correct when the
battery is removed.
Adjustment ineffective
- Check the connection of the voltage
reference to the A.V.R.
- Faulty diodes
- Induced short circuit
Check the A.V.R. connections (A.V.R. may
be faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Main field winding short-circuited
- Check the resistance
Increase the drive speed
(Do not touch the A.V.R. pot (P1) before
returning to the correct speed.)
- Faulty A.V.R.
- 1 faulty diode
- Check the speed: possibility of cyclic
irregularity
- Loose terminals
- Faulty A.V.R.
- Speed too low on load
(or U/F gradient set too high)
- Check the speed (or U/F gradient set too
high)
- Faulty rotating diodes
- Short-circuit in the main field. Check the
resistance
- Faulty induced excitaion
(*) Warning: For single-phase operation, check that the sensing wires coming from the A.V.R. are correctly connected to
the operating terminals (see the alternator manual).
Voltage
disappears
during
operation
Check the A.V.R., the
surge suppressor, the
rotating diodes and
replace any defective
components
- Exciter winding open circuit
The voltage does not return to the - Faulty induced excitation
rated value
- Faulty A.V.R.
- Main field open circuit or short-circuited
Warning: after setting-up or troubleshooting, replace all access panels or
covers.
169/209
9
Installation and maintenance
LEROY-SOMER
R250
A.V.R.
4 - SPARE PARTS
4.1 - Designation
Description
A.V.R.
Type
R 250
Code
AEM 110 RE 019
4.2 - Technical support service
Our technical support service will be pleased
to help you with any information needed.
For replacement part orders, it is necessary
to indicate the type and the code number of
the A.V.R.
Please contact your usual correspondant.
An extensive network of service centres is
available to rapidly supply any necessary
parts.
In order to ensure the correct operation and
safety of our machines, we strongly
recommend that original manufacturer’s
spare parts are used.
Failure to do so, will discharge the
manufacturer from liabilty in the case of
damage.
10
170/209
4067 en - 2009.05 / b
LEROY-SOMER
Installation and maintenance
R250
4067 en - 2009.05 / b
A.V.R.
171/209
11
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 ¤
www.leroy-somer.com
172/209
3
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
STAB. I EXC
1
4
2
50Hz
0
90 1
23
6
4 56
VOLT.
7
8
EXT.FREQ.
SET.
9
LAM
ON
LAM
OFF
KNEE
ONLY FOR
SPECIAL
CONFIG.
SERIES
0
SERIES
0 LSA 46.2/47.2
5000/6000
LSA 46.2/47.2
1 5000/6000
LEDS
FUSIBLES / FUSES
Installation & maintenance manual :
www.leroy-somer.com
VOIR NOTICE
SEE NOTICE
Installation and maintenance
5
MODE 2
65Hz
LAM OFF
60Hz
1 PHASE SENSING
2
3
STAT.
AVRs
SERIES
3
7000/8000 2
SERIES
7000/8000
LSA 49.1/50.2
S2
R 450
US
C
X2
Z1
E+ Z2 X1
E-
1
380V 220 110 0V
LSA 49.1/50.2
0
1
NORMAL
1 NORMAL
0 NORMAL
NORMAL
3 PAHASES SENSING
SHUNT / AREP
3
S1
173/209
PMG
1k
n to
RAPIDE 3
FAST
RAPIDE
FAST 2
3PH.
ive
be g
o
t
s
er
ual i
man e end us
h
This
t
50 Hz EXT FREQ
60 Hz SETTING
R 450
78
2
4531 en - 2012.03 / e
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
This manual concerns the alternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your AVR, you can look
forward to many years of trouble-free operation.
SAFETY MEASURES
Before using your machine for the first time,
it is important to read the whole of this
installation and maintenance manual.
WARNING
All necessary operations and interventions
on this machine must be performed by a
qualified technician.
Warning symbol for an operation capable
of damaging or destroying the machine
or surrounding equipment.
Our technical support service will be pleased
to provide any additional information you
may require.
The various interventions described in
this manual are accompanied by
recommendations or symbols to alert the
user to potential risks of accidents. It is vital
that you understand and take notice of the
various warning symbols used.
Warning symbol for general danger to
personnel.
Warning symbol for electrical danger to
personnel.
Note: LEROY-SOMER reserves the right to
modify the characteristics of its products
at any time in order to incorporate the
latest technological developments. The
information contained in this document may
therefore be changed without notice.
2
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LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
CONTENTS
1 - GENERAL INFORMATION ................................................................................................4
1.1 - Description.................................................................................................................... 4
1.2 - Characteristic................................................................................................................ 4
2 - POWER SUPPLY................................................................................................................ 5
2.1 - AREP excitation system................................................................................................5
2.2 - PMG excitation system..................................................................................................6
2.3 - SHUNT or separate excitation system...........................................................................7
3 - TECHNICAL CHARACTERISTICS.....................................................................................8
3.1 - Electrical characteristics................................................................................................8
3.2 - Configurations............................................................................................................... 8
3.3 - U/F and LAM functions................................................................................................12
3.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only)......... 12
3.5 - AVR options . .............................................................................................................. 13
4 - INSTALLATION - COMMISSIONING................................................................................14
4.1 - Electrical checks on the AVR.......................................................................................14
4.2 - Setting up.................................................................................................................... 14
4.3 - Electrical faults............................................................................................................ 17
5 - SPARE PARTS.................................................................................................................. 18
5.1 - Designation................................................................................................................. 18
5.2 - Technical support service............................................................................................18
All servicing or repair operations performed on the AVR should be undertaken by
personnel trained in the commissioning, servicing and maintenance of electrical and
mechanical components.
Copyright 2005: LEROY-SOMER MOTORS
This document is the property of:
LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
3
175/209
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
1 - GENERAL INFORMATION
1.1 - Description
1.2 - Characteristic
The connection is realised by “Faston”
connectors and the voltage sensing is
single - phase.
The R450 AVR is supplied in a casing
designed to be mounted on a panel with
dampers.
- Operating temperature: - 30°C to + 65° C.
- Storage temperature: - 55°C to + 85°C.
- Shocks on the base: 9 g depending on the
3 axes.
- Vibrations: less than 10 Hz, 2 mm
half-peak amplitude 10 Hz to 100 Hz: 100
mm/s, above 100 Hz: 8 g.
WARNING
The AVR is IP00, it must be incorporated
in an environment which ensures it a
IP20 protection.
140 mm
115 mm
4 holes Ø 6.5 mm
R 450
4 56
23
1
4
2
3
50Hz
0
5
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
MODE 2
0
SERIES
1
SERIES
0 LSA 46.2/47.2
5000/6000
LSA 46.2/47.2
1 5000/6000
STAB. I EXC
78
90 1
2
VOLT.
EXT.FREQ.
SET.
9
8
7
0
2
50 Hz
60 Hz
LAM
ON
LAM
OFF
ONLY FOR
SPECIAL
CONFIG.
6
3
3
0 NORMAL
NORMAL
1
S1
NORMAL
1 NORMAL
1 PHASE SENSING
KNEE
65Hz
LAM OFF
SERIES
7000 /8000
LSA 49.1 /50.2
SERIES
7000 /8000 2
LSA 49.1 /50.2
3
PMG
1k
3 PAHASES SENSING
SHUNT / AREP
RAPIDE 3
FAST
RAPIDE
FAST 2
3PH.
Rotating switch
- Lam and U/F
- Voltage
- Excitation
50 Hz EXT FREQ
60 Hz SETTING
FUSIBLES / FUSES
200 mm
Installation & maintenance manual :
www.leroy-somer.com
Quad
droop
LEDS
STAT.
175 mm
S2
P4
VOIR NOTICE
SEE NOTICE
380V 220 110 0V
E- E+ Z2 X1 Z1 X2
4
176/209
C
US
P1
Voltage
P2
Stability
P3
Excitation
Overrun
indications
Fuses 10A
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
2 - POWER SUPPLY
characteristic), the second one has a
voltage proportional to the stator current
(compound characteristic : Booster effect).
The power supply voltage is rectified and
filtered before being used by the AVR
monitoring transistor.
This system provides the machine with a
short-circuit current capacity of 3 IN for 10 s.
The rotating switch should be in the AREP
position (see 3.2.3).
Both the SHUNT/AREP & PMG excitation
systems are controlled by the AVR.
2.1 - AREP excitation system
With AREP excitation, the electronic AVR is
powered by two auxiliary windings which
are independent of the voltage sensing
circuit.
The first winding has a voltage proportional
to the alternator main voltage (Shunt
STATOR : 6 wires ( T1 to T6)
STATOR : 12 wires ( T1 to T12)
MAIN FIELD
AREP SYSTEM
Aux. windings
T1 T7
T8
T3 T9
T11
T6 T12
R 450
T5
50 Hz EXT FREQ
60 Hz SETTING
4 56
1
2
3
50Hz
0
4
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
0
SERIES
1
SERIES
0 LSA 46.2/47.2
5000/6000
LSA 46.2/47.2
1 5000/6000
STAB. I EXC
78
90 1
2
VOLT.
8
7
6
EXT.FREQ.
SET.
9
LAM
ON
LAM
OFF
ONLY FOR
SPECIAL
CONFIG.
KNEE
LAM OFF
3
3
0
0 NORMAL
NORMAL
1
NORMAL
1 NORMAL
S1
5
MODE 2
65Hz
60Hz
1 PHASE SENSING
SERIES
7000 /8000
LSA 49.1 /50.2
SERIES
7000 /8000 2
LSA 49.1 /50.2
3
PMG
1k
3 PAHASES SENSING
SHUNT / AREP
RAPIDE 3
FAST
RAPIDE
FAST 2
3PH.
2
T4 T10
9 Green
Field
11 Red
6-
10 Yellow
Armature
23
5+
12 Black
Varistor
T2
S2
LEDS
STAT.
FUSIBLES / FUSES
Installation & maintenance manual :
www.leroy-somer.com
VOIR NOTICE
SEE NOTICE
380V 220 110 0V
E- E+ Z2 X1 Z1 X2
according to voltage
C
US
10 Yellow
11 Red
12 Black
9 Green
5
177/209
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
2.2 - PMG excitation system
The AVR monitors the alternator output
voltage by adjusting the excitation current.
The rotating switch should be in the PMG
position (see 3.2.3).
With PMG excitation, a permanent magnet
generator (PMG) added to the alternator
supplies the AVR with voltage which is
independent of the main alternator winding.
This system provides the machine with a
short-circuit current capacity of 3 IN for 10 s.
STATOR : 6 wires ( T1 to T6)
STATOR : 12 wires ( T1 to T12)
MAIN FIELD
PMG SYSTEM
T1 T7
T2
T8
T3 T9
T11
T6 T12
Varistor
Armature
PMG
5+
Field
6-
T4 T10
R 450
16
15
50 Hz EXT FREQ
60 Hz SETTING
14
0
2
4 56
23
2
3
STAB. I EXC
1
4
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
MODE 2
SERIES
1
SERIES
0 LSA 46.2/47.2
5000/6000
LSA 46.2/47.2
1 5000/6000
50Hz
0
5
90 1
0
2
VOLT.
8
7
EXT.FREQ.
SET.
9
LAM
ON
LAM
OFF
ONLY FOR
SPECIAL
CONFIG.
6
3
3
0 NORMAL
NORMAL
1
S1
NORMAL
1 NORMAL
60Hz
1 PHASE SENSING
KNEE
LAM OFF
65Hz
SERIES
7000 /8000
LSA 49.1 /50.2
SERIES
7000 /8000 2
LSA 49.1 /50.2
3
PMG
1k
3 PAHASES SENSING
SHUNT / AREP
RAPIDE 3
FAST
RAPIDE
FAST 2
3PH.
78
S2
LEDS
STAT.
FUSIBLES / FUSES
Installation & maintenance manual :
www.leroy-somer.com
VOIR NOTICE
SEE NOTICE
380V 220 110 0V
E- E+ Z2 X1 Z1 X2
according to voltage
16
15
6
178/209
14
C
US
T5
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
2.3 - SHUNT or separate excitation
system
With SHUNT excitation, the AVR is powered
by the main winding (100V to 140V 50/60 Hz ) by using X1, X2 on the AVR.
The rotating switch should be in the SHUNT/
AREP position (see 3.2.3).
STATOR : 6 wires ( T1 to T6)
STATOR : 12 wires ( T1 to T12)
MAIN FIELD
SHUNT SYSTEM
T1 T7
T2
T8
T3 T9
Varistor
Armature
6-
T4 T10
R 450
T11
T6
T12
4 56
1
2
3
50Hz
0
4
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
SERIES
1
SERIES
0 LSA 46.2/47.2
5000/6000
LSA 46.2/47.2
1 5000/6000
STAB. I EXC
78
90 1
2
VOLT.
8
7
6
EXT.FREQ.
SET.
9
LAM
ON
LAM
OFF
ONLY FOR
SPECIAL
CONFIG.
KNEE
LAM OFF
3
3
0
0 NORMAL
NORMAL
1
NORMAL
1 NORMAL
S1
5
MODE 2
65Hz
60Hz
1 PHASE SENSING
SERIES
7000 /8000
LSA 49.1 /50.2
SERIES
7000 /8000 2
LSA 49.1 /50.2
3
PMG
1k
3 PAHASES SENSING
SHUNT / AREP
RAPIDE 3
FAST
RAPIDE
FAST 2
3PH.
2
T5
50 Hz EXT FREQ
60 Hz SETTING
0
Field
23
5+
S2
LEDS
STAT.
FUSIBLES / FUSES
Installation & maintenance manual :
www.leroy-somer.com
VOIR NOTICE
SEE NOTICE
380V 220 110 0V
E- E+ Z2 X1 Z1 X2
C
US
X1
X2
7
179/209
LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
3 - TECHNICAL CHARACTERISTICS
3.1 - Electrical characteristics
- maximum power supply: 150V - 50/60 Hz
- Rated overload current: 10 A - 10 s
- Electronic protection:
- In the case of a short-circuit, the excitation
current is reduced to a value less than 1A
after 10 s
- In the event of loss of voltage reference,
the excitation current is reduced to a value
less than 1A after 1s for AREP/SHUNT, 10 s
for PMG.
- In the event of overexcitation, the current
is reduced as indicated in the next diagram
(see 3.2.1.4).
- Fuses: F1 on X1 and F2 on Z2 10A, 250V.
- Voltage sensing
• 0-110 V terminals = 95 to 140 V
• 0-220 V terminals = 170 to 260 V
• 0-380 V terminals = 340 to 528 V
For other voltages, a transformer should be
used.
- Voltage regulation:± 0.5%.
- Current sensing: (parallel operation): input
S1, S2 intended for 1 C.T. < 2.5 VA cl1,
secondary 1 A or 5 A.
3.2 - Configurations:
3.2.1 - Settings
3.2.1.1 - Voltage
Voltage adjustment via potentiometer P1 in
the ranges described in the table below:
For 50 and 60 Hz
High range
Low range
Max.
320V < Un ≤ 530 V
80 V ≤ Un ≤ 320 V
WARNING
The allowed adjustment range is ±5%;
when the setting exceeds these limits,
please check that it is conform with the
power table.
3.2.1.2 - Quadrature droop:
Quadrature
droop
adjustment
via
potentiometer P4 within a range :
- from 0 to 8% with a PF=0.8 for 400V
applications.
- From 0 to 14% with a PF=0.8 for 240V
applications.
- From 0 to 8% for 110V applications with a
step-up transformer (ratio of 4) placed on
the voltage reference.
The potentiometer P4 has a non linear
response. Then, when a 1A secondary CT is
connected the effective range starts from
the the second 1/3 of P4 range and in the
case of a 5A secondary CT the effective
range starts from the first 1/3.
When a 5A CT is used, the adjustment range
is higher, so P4 must be set to the first 1/4
(anti-clockwise) and then progressively
increase it.
WARNING
The CT must be connected.
3.2.1.3 - Stability:
Stability adjustment via potentiometer P2.
Selection of rotating switch according to the
machine type and the response time as
indicated in paragraph 3.2.3.
3.2.1.4 - Excitation limitation:
Excitation limitation adjustment via
potentiometer P3 as described below.
The excitation current limitation threshold in
steady state is set by a potentiometer at
110% of the rated value. The adjustment is
made by the operator during the on-load test
at rated power by tuning the potentiometer.
When the excitation current exceeds this
value, a counter is activated at the speed of
one record per second for 90 s. When this
time is elapsed, the current is reduced to the
value of the rated excitation current. If in the
meantime the excitation current drops
below the threshold value, the counter
counts down at the same speed.
8
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LEROY-SOMER
Installation and maintenance
4531 en - 2012.03 / e
R 450
AVRs
excitation current must be limited to
9 A ± 0.5 A.
WARNING
The limitation threshold must be
adjustable between 1 and 5.5 A. The
genset breaker must be open during the
short circuit. If the genset is restarted in
short circuit, there is a excitation build
up during 10s again at the maximum
value.
Operation between 3 and 6 In when
short-circuited:
The excitation current ceiling during a
short-circuit equals 2.9 times the fixed
threshold when setting the permitted
excitation ceiling in continuous operation.
When the threshold is exceeded for a period
= 10 s the current is reduced to a value
between 0.5 and 0.7 A (shutdown).
In all operating conditions the maximum
Overrun indications:
One green LED:
- Lights up when the excitation current is
below the continuous operation threshold
It signals the AVR normal operation.
- Turns off when the excitation current ceiling
used to obtain short-circuit operation is
reached and when the excitation current is
reduced to the shutdown value.
- Flashes when the over excitation counter
is decrementing.
NB: After an obvious short-circuit, the
voltage is limited to 70% of the rated voltage.
This avoids overvoltages on machines
whose no-load excitation current is below
the “lower current” threshold (only in AREP).
I exc(A)
2.9x I threshold
(max. 9.5 A)
9.5
Diagram 1
(Maximum current I exc)
P3
I threshold
(1...5.5A)
Shutdown
0.5 ~ 0.7
t(s)
Activation of
90 s tempo.
Decrease of
90 s tempo.
Activation of
90 s tempo.
Activation of
10 s tempo.
10s tempo. elapsed :
shutdown apllication
Red led
Green led
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AVRs
I exc(A)
2.9x I threshold
(max. 9.5 A)
9.5
Diagram 2
(Maximum current I exc)
P3
I threshold
(1...5.5A)
Shutdown
0.5 ~ 0.7
t(s)
Activation of
90 s. tempo
90 s. tempo elapsed : application
of permanent limitation
Red led
Green led
One red LED:
- Lights up simultaneously with the green led
when the continuous operation threshold is
reached for more than 90 s and the excitation
current is reduced to the continuous
operation threshold. It is used to set the
excitation current ceiling
- Turns off when the excitation current is less
than the setting value (< 110% In)
- Flashes when the excitation current is
above the continuous operation threshold
during less than 90 s.
Green LED stays on,
- flashes when the excitation current has
reached the ceiling in < 10s with PMG
excitation.
- ftays on if Iexc = I Shutdown.
WARNING
If the overload protection is activated, a
voltage drop possibly exceeding 10% of
the reference voltage will be observed.
The AVR does not provide undervoltage
protection. The customer will need to
make sure that their installation is
correctly protected against undervoltages.
During load shedding, an overvoltage is
observed, which will disappear in a few
seconds.
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R 450
AVRs
KNEE
65Hz
LAM OFF
78
456
7
6
2
5
3
4
60Hz
RAPIDE 3
FAST
RAPIDE
FAST 2
For Pavers and hydraulic applications,
select positions 0 (50 Hz) or 3 (60 Hz).
0 NORMAL
NORMAL
PMG
NORMAL
1 NORMAL
0: AREP excitation and normal time
response.
3: AREP excitation and fast time response.
1: PMG excitation and normal time response.
2: PMG excitation and fast time response.
For SHUNT applications, AREP excitation
must be selected.
3.2.4 Rotating switch: voltage sensing
1 PHASE SENSING
SERIES
LSA 49.1/50.2
7000/8000
3
SERIES
LSA 49.1/50.2
SERIES
3
0 LSA 46.2/47.2
5000/6000
1
WARNING
3
0
- Pos 0: Change in the voltage according to
the U/F ratio, knee-point position at 48 Hz.
- Pos 1: Change in the voltage according to
the 2U/F, knee-point position at 48 Hz.
- Pos 2: Change in the voltage according to
the self auto-adaptating LAM combined with
2U/F, knee-point position at 48 Hz.
- Pos 3: Change in the voltage according to
the U/F ratio, knee-point position at 58 Hz
- Pos 4: Change in the voltage according to
the 2U/F, knee-point position at 58 Hz.
- Pos 5: Change in the voltage according to
the self auto-adaptating LAM combined with
2U/F, knee-point position at 58 Hz.
- Pos 6: Change in the voltage according to
the U/F ratio, knee-point position at 65 Hz
(Tractelec application and variable speed
above 1800 rpm).
- Pos 7: Special (not used).
- Pos 8: Change in the voltage according to
the U/F ratio, knee-point position at 48 Hz or
58 Hz according to selection of the frequency
by an external contact.
- Pos 9: Change in the voltage according to
LAM 1, knee-point position at 48 Hz or 58 Hz
according to selection of the frequency by
an external contact
AREP
1
ONLY FOR
SPECIAL
CONFIG.
1
LAM
OFF
LAM
MODE 1
LAM
MODE 2
LAM
OFF
LAM
MODE 1
LAM
MODE 2
0
8
901
23
LAM
OFF
50Hz
0
2
EXT.FREQ.
LAM SET.
9
ON
3.2.3 Rotating switch: excitation type
and time response
2
3.2.2 - Rotating switch selection: LAM
and U/F
7000/8000 2
SERIES
LSA 46.2/47.2
1 5000/6000
ONLY WITH
EXTERNAL R731 MODULE
3 PHASES SENSING
0: Single phase sensing
- LSA46.2/47.2 series.
3: Single phase sensing
- LSA49.1/50.2 series.
1: Three-phase sensing with optional
module R731
- LSA46.2/47.2 series.
2: Three-phase sensing with optional
module R731
- LSA49.1/50.2 series.
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AVRs
3.3 - U/F and LAM function
3.3.1 - Frequency variation compared
with voltage (without LAM)
Bend
Voltage
48 Hz
100 %
U/UN
57.5 Hz
50 Hz
60 Hz
Frequency
50 Hz
60 Hz
Hz
3.3.2.2 - Soft voltage recovery function
During load impacts, the function helps the
genset to return to its rated speed faster with
a gradual increase in voltage according to
the principle:
- If the speed drops between 46 and 50 Hz
(in 50Hz operation), the rated voltage is
recovered by following a fast gradient.
- If the speed drops below 46 Hz, since the
engine needs more help, the voltage follows
a slow gradient as it returns to the reference
value.
3.3.2 - LAM (Load Acceptance Module)
characteristics
3.3.2.1 - Voltage drop
The LAM system is integrated in the AVR. As
standard it is active.
Role of the LAM:
On application of a load, the genset rotation
speed decreases. When it falls below the
preset frequency threshold, the LAM causes
the voltage to drop proportionately to the
frequency (LAM1) or to the active power
(LAM2) depending the the rotating switch
position. This reduces the active load scale
applied until the speed returns to its rated
value.
Hence the LAM can be used either to reduce
the speed variation (frequency) and its
duration for a given applied load, or to
increase the applied load possible for one
speed variation (turbo-charged engine).
To avoid voltage oscillations, the trip
threshold for the LAM function should be set
approximately 2 Hz below the rated
frequency.
U
Drop N 46 Hz
Drop N > 46 Hz
3.4 - Typical effects of the LAM with
a diesel engine with or without a
LAM (U/F only)
3.4.1 - Voltage
0,9
(U/f)
without LAM
with
LAM
0,8
Time
1s
0
2s
3s
3.4.2 - Frequency
Max. speed drop
with
LAM
Voltage
UN
0,9
U/f
LAM
0,85 UN
0
Transient voltage drop
UN
fN
Voltage
Time
0
without
LAM
0,8
0
48 or 58 Hz
ST3
fC
50 or 60 Hz
fN
12
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1s
2s
Time
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R 450
AVRs
3.4.3 - Power
• Equalization of voltages before
paralleling (3 F).
• Possibility of coupling to the mains of
alternators already running in parallel (4F).
Load on the
shaft (kW)
LAM
0
-R729 module: same as R726 with
additional functions.
• Detection of a diode fault.
• 4-20 mA input.
• Possibility of kVAR regulation.
Variation in the load
Load shedding due to LAM
1s
2s
Time
3s
3.5 - AVR options
- Current transformer for parallel operation of....../1 A or 5 A according to the potentiometer P4 position.
-Voltage transformer (adaptation)
-Voltage control: with an isolated
D.C. current source applied to the terminals
used for the external potentiometer:
• Internal impedance 1.5 kΩ.
• A variation of ± 0.5 V corresponds to a
voltage adjustment of ± 10%.
-Remote voltage adjustment potentio
meter.
For a range of variation:
± 5% : 470 Ω
± 10% : 1 kΩ
the power of the potentiometer can be
0.5 W, 2 W or 3 W.
The potentiometer input must be
isolated. Do not connect it to the ground.
-R 731 module: 3-phase voltage sensing
200 to 500 V, compatible with parallel
operation in balanced installations.
-R 734 module: 3-phase current and
voltage sensing for parallel operation on
unbalanced installations (unbalance >
15%).
- R 726
module: regulation system
changed to “4 - function” (see the
maintenance manual and connection
diagram).
• PF regulation (2F) .
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AVRs
4-INSTALLATION-COMMISSIONING
4.1 - Electrical checks on the AVR
- Check that all connections have been
made properly as shown in the attached
wiring diagram.
- Check the rotating switches selections
- frequency,
- type of alternator,
- normal position (response time),
- external potentiometer,
- rated voltage,
- secondary current of the CT used,
- type of excitation.
- R450 optional operating modes
4.2 - Setting up
Factory setting
Pot.
Voltage
minimum fully
anti-clockwise
Action
400 V - 50 Hz
P1
Stability
Not set
(centre position)
P2
Excitation ceiling
- Factory-sealed
10 A
maximum
P3
Voltage quadrature droop
(// operation with C.T.)
- 0 quadrature droop fully
anti-clockwise
Not set
(fully
anti-clockwise)
P4
Stability adjustments in standalone
operation
b) Install a D.C. analogue voltmeter (needle
dial) cal. 100 V on terminals F+, F- and an
A.C. voltmeter cal. 300 - 500 or 1000 V on
the alternator output terminals.
c) Check the rotating switch selection.
The various adjustments during tests
must be made by a qualified engineer. It
is essential that the drive speed
specified on the nameplate is reached
before commencing adjustment. After
operational testing, replace all access
panels or covers.
The AVR is used to make
adjustments to the machine.
any
d) Voltage potentiometer P1 at minimum,
fully anti-clockwise.
e) Stability potentiometer P2 around 1/3 in
from the anti-clockwise stop.
f) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for
60 Hz.
Before using the AVR, make sure that
the rotating switches have been
correctly configured with AREP/SHUNT
or PMG excitation
g) Set the output voltage to the desired
value using P1.
- Rated voltage UN for solo operation
(eg. 400 V)
- Or UN + 2 to 4% for parallel operation with
C.T. (eg. 410 V -)
If the voltage oscillates, use P2 to make
adjustments (try both directions), observing
the voltage between F+ and F- (approx.
10 V D.C.). The best response time is
obtained at the limit of the instability. If no
stable position can be obtained, try selecting
the fast position.
a) Initial potentiometer settings (see table
below)
h) Check LAM operation: depending on the
rotating switch selection.
4.2.1 - Setting up the R450
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i) Vary the frequency (speed) around 48 or
58 Hz according to the operating frequency,
and check the change in voltage from that
observed previously (~ 15%).
j) Readjust the speed of the genset to its
rated no-load value.
Adjustments in parallel operation
Before starting work on the alternator, make
sure that the speed droop is identical for all
engines.
k) Preset for parallel operation (with C.T.
connected to S1, S2)
- Potentiometer P4 (quadrature droop) in
1/4 position in the case of 5A CT and at 1/2
position in the case of 1A CT.
Apply the rated load (PF = 0.8 inductive).
The voltage should drop by 2 to 3% (400 V).
If it increases, check that neither V and W
nor S1 and S2 have been reversed.
l) The no-load voltages should be identical
for all the alternators intended to run in
parallel.
- Couple the machines in parallel.
- By adjusting the speed, try to obtain 0 kW
power exchange.
- By altering the voltage setting P1 on one of
the machines, try to cancel (or minimise) the
current circulating between the machines.
- From now on, do not touch the voltage
settings.
m) Apply the available load (the setting is
only correct if a reactive load is available)
- By altering the speed, match the kW (or
divide the rated power of the units
proportionally)
- By altering the quadrature droop
potentiometer P4, match or divide the
currents.
4.2.2 - Max. excitation adjustment
(excitation ceiling)
In standard setting, the potentiometer P3 is
in maximum position.
However, for applications requiring an
overload protection (see 3.2.1.4), the
excitation ceiling must be adjusted by using
the following procedures in AREP and PMG.
Method 1 :
-Connect the AVR to the alternator
-apply load to 110% of rated machine rated
at PF=0.8, the green led is on and the red
one is off.
-record the excitation current value
-adjust P3 until obtaining the red led flashing,
the green one is always on.
-decrease the load to 100% and make sure
that the red led is off.
- Increase the load at 115%, check that the
red LED flashes during 90 seconds and that
the excitation current is brought back to the
above adjusted value (Iex adjusted).
Method 2 :
The rated excitation current (see machine
plate) must be multiplied by 1.1 and the
obtained value is used to set the
potentiometer P3 at the right position.
The following table must be used.
Position of
P3
I exc (A)
8h
1
9h
1.55
10h
1.95
11h
2.5
12h
3.15
13h
3.65
14h
4.25
15h
4.7
16h
5.15
12H
8H
16H
P3
NB: In the case of a permanent short-circuit,
the excitation current must reach 2.9 x Iex
adjusted (limited to 9.5A), during 1 second
in AREP or 10 seconds in PMG and shuts
down to a value less than 1A.
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AVRs
When the excitation current is set to the
rated value, a voltage dip is observed in
excitation current limit when the
limitation is activated and the current
limit is reached.
4.2.3 - Special type of use
WARNING
The excitation circuit F+, F- must not be
left open when the machine is running:
this will irreparably damage the AVR.
The exciter is switched off by disconnecting
the AVR power supply (1 wire on each
auxiliary winding) - contact rating 16 A 250 V A.C.
Connection is identical for resetting the AVR
internal protection.
If field weakening is used, provide field
forcing.
4.2.3.3 - R450 field forcing
(400V - 10A)
X2
Z1
X1
Z2
E+
E-
4.2.3.1 - R450 (SHUNT) field weakening
X2
Z1
X1
Z2
E+
E-
t
Diode
-
+
Battery (B Volt)
Exciter field winding
Field forcing
B Volt
t
Time
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2)
Contact rating: 16 A - 250 V A.C.
Applications
B Volt
Time t
Guaranteed voltage build-up
12 (1A)
1-2s
Parallel operation, de-energized
12 (1A)
1-2s
4.2.3.2 - R450 (AREP/PMG) field
weakening
Parallel operation, at standstill
12 (1A)
5 - 10 s
Frequency starting
12 (1A)
5 - 10 s
Sustained voltage on overload
12 (1A)
5 - 10 s
X2
Z1
X1
Z2
E+
E-
16
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AVRs
4.3 - Electrical faults
Fault
Action
Measurements
Check/Cause
The alternator builds up and its
voltage is still correct when the
battery is removed
- Lack of residual magnetism
No voltage at Connect a new battery The alternator builds up but its
no load on
of 4 to 12 V to terminals voltage does not reach the rated
start-up
F- and F+, respecting value when the battery is removed
the polarity, for 2 to 3
seconds
The alternator builds up but its
voltage disappears when the
battery is removed
Voltage too
low
Check the drive speed
- Check the connection of the voltage
reference to the AVR
- Faulty diodes
- Armature short-circuit
- Faulty AVR
- Field windings disconnected
- Revolving field coil open circuit. Check the
resistance
- Check the AVR connections and settings
(AVR faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Revolving field coil short-circuited
- Check the resistance
Correct speed
Increase the drive speed
(Do not touch the AVR voltage pot. (P1)
before running at the correct speed)
Speed too low
Voltage too
high
Adjust AVR voltage
potentiometer
Adjustment ineffective
- Faulty AVR
- 1 faulty diode
Voltage
oscillations
Adjust AVR stability
potentiometer
If no effect: try normal/fast
recovery modes
- Check the speed: possibility of cyclic
irregularity
- Loose connections
- Faulty AVR
- Speed too low when on load
(or U/F knee-point set too high)
Voltage
correct at no
load and too
low when on
load (*)
Run at no load and
check the voltage
between F+ and F- on
the AVR
Voltage between F+ and FAREP/PMG < 10 V
- Check the speed
(or U/F knee-point set too high)
Voltage between F+ and FAREP/PMG > 15 V
- Faulty rotating diodes
- Short-circuit in the revolving field coil.
Check the resistance
- Faulty exciter armature
(*) Caution: For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to
the operating terminals.
Voltage
disappears
during
operation (**)
Check the AVR, the
surge suppressor, the
rotating diodes, and
replace any defective
components
The voltage does not return to the - Exciter winding open circuit
rated value
- Faulty exciter armature
- Faulty AVR
- Revolving field coil open circuit or
short-circuited
- Overload (see LED)
(**) Caution: Internal protection may be activated (overload, open circuit, short-circuit)
Caution: After operational testing or
troubleshooting, replace all access
panels or covers.
17
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R 450
AVRs
5 - SPARE PARTS
5.1 - Designation
Description
Type
Voltage regulator R 450
(AVR)
Code
AEM 110 RE 031
5.2 - Technical support service
Our technical support service will be pleased to
provide any additional information you may
require.
When ordering spare parts, you should indicate
the AVR type and code number.
Address your enquiry to your usual contact.
Our extensive network of service centres can
dispatch the necessary parts without delay.
To ensure correct operation and the safety of our
machines, we recommend the use of original
manufacturer spare parts.
In the event of failure to comply with this advice,
the manufacturer cannot be held responsible for
any damage.
18
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AVRs
19
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www.leroy-somer.com
192/209
Appendix C - Common spare parts
R230U
Rental Power
ENGINE
VOLVO
TAD733GE
GENLUB
9.3.
Starter relay
330052259
X1
Radiator cap
31802000304
X1
Starter motor brush holder
330052260
X1
Alternator belt
330051895
X1
Fan belt
330051887
X1
Thermostat
330051879
X1
Thermostat seal
330051876
X1
Oil pressure switch
330052271
X1
Temperature sensor
330052075
X1
Tachometric control
330052262
X1
Sensor
330052269
X1
Temperature sensor
330052261
X1
Turbo air temperature sensor
330052258
X1
Alarm oil pressure sensor
330051863
X1
Alarm water temperature
sensor
330052506
X1
x 20 L
330910115
x 208 L
330910095
X1
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GENCOOL
x 20 L
330910098
x 60 L
330910099
x 210 L
330910100
X1
330570107 + 330570108
X1
330560196 + 330510016
X1
330560039
X1
ALTERNATOR
LEROY-SOMER
LSA46.2M5
Note:
Diode bridge
330410126
X1
Varistor
330410109
X1
For all technical assistance or spare part requests, contact your nearest SDMO agent.
194/209
SID
PID
PPID
FMI
28
97
98
Comment
3
Throttle Voltage high, short to V+
Short to V+
4
Throttle Voltage low, short to V-
Short to V-
Throttle #2 Position
3
Throttle Voltage high, short to V+
Short to V+
4
Throttle Voltage low, short to V-
Short to V-
14
Throttle voltage out of range
84
94
Description
Throttle #3 Position
29
91
Perkins
CID
Volvo
SPN
Appendix D - List of John Deere - Volvo and Perkins fault codes
John Deere
9.4.
Vehicle speed
91
91
2
Vehicle invalid or missing
31
Vehicle speed mismatch
132
Accelerator pedal position
3
Throttle Voltage high, short to V+
4
Throttle Voltage low, short to V-
7
Throttle calibration invalid
8
PWM throttle abnormal pulse width
9
Throttle invalid (CAN value)
10
Throttle voltage out of range low
13
Throttle calibration aborted
14
Throttle voltage out of range
94
Not possible with Genset
application
FMI not determined for all
VOLVO’s
Not possible with genset
application, codes declared
by the CAN J1587 for
VOLVO.
Fuel rail pressure sensor
1
Fuel supply pressure extremely low
3
Fuel rail pressure input voltage high
Short to V+
4
Fuel rail pressure input voltage low
Short to V-
5
Fuel rail pressure sensor open circuit
10
Fuel rail pressure lost detected
13
Fuel rail pressure higher than expected
16
Fuel supply pressure moderately high
17
Fuel rail pressure not developed
18
Fuel supply pressure moderately low
97
Water in fuel sensor
0
Water in fuel continuously detected
3
Water in fuel input voltage high
Short to V+
Short to V-
4
Water in fuel input voltage low
16
Water in fuel detected
31
Water in fuel detected
1
Oil level value below normal
3
Oil level sensor input voltage high
Short to V+
4
Oil level sensor input voltage low
Short to V-
5
Oil level sensor open circuit
98
Oil level sensor
195/209
100
102
273
PID
PPID
FMI
100
1
Engine oil pressure extremely low
Oil pressure sensor input voltage high
Short to V+
4
Oil pressure sensor input voltage low
Short to V-
5
Oil pressure sensor open circuit
17
Engine oil pressure low
18
Engine oil pressure moderately low
31
Oil pressure detected, motor stopped
102
Manifold air pressure sensor
0
Manifold air pressure above normal
1
15
Manifold air pressure below normal
Incoherent measurement of the oil
pressure
Manifold air pressure sensor input
Short to V+
voltage high
Manifold air pressure sensor input
Short to Vvoltage low
Manifold air pressure moderately low
16
Manifold air pressure low
0
Turbo speed too high
5
Turbo speed sensor circuit open
6
Sensor shorted to earth
8
Speed signal invalid
Intermittent
problem
with
speed
information
Manifold air temperature sensor
4
103
Turbo speed sensor
31
105
0
15
Manifold air temperature extremely high
Manifold air temperature sensor input
voltage high
Manifold air temperature sensor input
voltage low
Manifold air temperature sensor open
circuit
Air temperature very high.
16
Manifold air temperature moderately high
3
4
5
106
Air inlet pressure sensor
0
3
5
107
Comment
3
3
106
Description
Oil pressure sensor
2
105
Perkins
100
SID
Volvo
CID
John Deere
SPN
107
Air inlet pressure above normal
Air inlet pressure sensor input voltage
high
Air inlet pressure sensor open circuit
Air filter differential pressure sensor
0
3
4
5
31
Air filter restriction high
Air filter differential pressure sensor input
voltage high
Air filter differential pressure sensor input
voltage low
Air filter differential pressure sensor open
circuit
Air filter restriction high
196/209
Short to V-
274
PID
PPID
FMI
108
3
4
17
110
110
15
Coolant temperature high least severe
16
Coolant temperature moderately high
17
Water temperature very low
31
Coolant temperature high
111
Engine coolant level low
1
Engine coolant level low
3
Coolant level sensor input voltage high
4
Coolant level sensor input voltage low
153
Crankcase pressure sensor
0
1
Value above normal
Crankcase pressure sensor input voltage
high
Crankcase pressure sensor open circuit
Fuel pressure sensor in the common
rail
Fuel pressure too low
3
Input voltage of the pressure sensor high
Short to V+
Short to V-
3
5
157
4
Input voltage of the pressure sensor low
10
Loss of fuel pressure detected
16
Fuel pressure moderately high
17
Fuel ramp pressure not reached
18
Oil pressure moderately low
158
Battery voltage sensor
1
Voltage above normal
17
ECU power down error
160
Wheel speed sensor
2
164
ECM option,
connected
Coolant level sensor
0
168
High barometric pressure
5
4
158
Not use with EDC III and
EMS2
Air pressure invalid
High barometric pressure sensor short to
high
High barometric pressure sensor short to
low
Coolant temperature extremely high
Coolant temperature sensor input voltage
high
Coolant temperature sensor input voltage
low
Coolant temperature sensor open circuit
3
153
Comment
Coolant temperature sensor
0
111
Description
Barometric pressure sensor
2
110
Perkins
108
SID
Volvo
CID
John Deere
SPN
164
Wheel speed input noise
Injection pressure control
168
Electrical system voltage
2
Electrical system voltage low
197/209
sensor
not
172
PID
PPID
FMI
172
4
5
15
16
174
0
15
16
Fuel temperature moderately high
31
Fuel temperature sensor faulty
4
175
Oil temperature sensor
0
Oil temperature extremely high
3
Oil temperature sensor input voltage high
4
Oil temperature sensor input voltage low
5
Oil temperature sensor open circuit
177
Transmission oil temperature sensor
9
189
190
228
Transmission oil temperature invalid
Rated engine speed
190
0
Engine speed de rated
31
Engine speed de rated
190
Engine speed sensor
0
Overspeed extreme
2
Engine speed sensor data intermittent
9
Engine speed sensor abnormal update
11
Engine speed sensor signal lost
12
Engine speed sensor signal lost
15
Overspeed
16
Overspeed moderate
13
Engine timing abnormal calibration
261
252
252
234
253
Speed sensor calibration
Software
11
281
Comment
Inlet
air
temperature
sensor for PERKINS
Ambient air temperature sensor input Inlet air temperature sensor
voltage high
input voltage high
Ambient air temperature sensor input Inlet air temperature sensor
voltage low
input voltage low
Ambient air temperature sensor open
circuit
High Inlet air temperature
alarm-warning
High Inlet air temperature
alarm-action alert
Fuel temperature sensor
Fuel temperature high most severe
Fuel temperature sensor input voltage
high
Fuel temperature sensor input voltage
low
Fuel temperature high
3
175
Description
Ambient air temperature sensor
3
174
Perkins
172
SID
Volvo
CID
John Deere
SPN
Incorrect engine software
Check system parameters
2
Incorrect parameters
3
Action alert output open/short to B+
4
Action alert output short to ground
5
Action alert output open circuit
281
Action alert output status
198/209
Not possible with Genset
application
282
285
PID
PPID
FMI
3
Overspeed output open/short to B+
4
Overspeed output short to ground
285
4
323
324
286
Oil pressure output open/short to B+
4
Oil pressure output short to ground
5
Oil pressure output open circuit
323
Shutdown output status
3
Shutdown output open/short to B+
4
Shutdown output short to ground
5
Shutdown output open circuit
324
Warning output status
3
Warning output open/short to B+
4
Warning output short to ground
5
Warning output open circuit
0
15
Temperature in the EGR extremely high
Input voltage of the temperature sensor
Short to V+
high
Input voltage of the temperature sensor
Short to Vlow
Temperature in the EGR high
16
Temperature in the EGR moderately high
Temperature sensor in the EGR valve.
3
4
443
ENGINE RUN output status
3
Engine run output open/short to B+
4
Engine run output short to B-
523
Gear selection
9
608
132
608
98
611
262
Gear selection invalid
Not possible with Genset
application
Data link faulty J1587 Start/Stop
redundancy / J1939 communication
bus
Redundancy of the accelerator
Redundancy
of
the
Stop/start
information
Injector wiring status
250
608
620
Comment
Coolant temperature output status
Coolant temperature lamp open/short to
B+
Coolant temperature lamp short to
ground
Oil pressure output status
3
412
443
Description
Overspeed output status
3
286
Perkins
282
SID
Volvo
CID
John Deere
SPN
3
Injector wiring shorted to power source
4
Injector wiring shorted to ground
232
5 Volt sensor power supply
3
Sensor power supply open/short to B+
4
Sensor power supply short to ground
199/209
FMI not
VOLVO
informed
by
626
PID
PPID
FMI
45
3
4
5
627
Perkins
SID
Volvo
CID
John Deere
SPN
Description
Comment
Start enable device (intake heater and
ether)
Start enable device output short to B+
Not used, the control panel
Start enable device output short to
is in charge of managing the
ground
start enable device
Start enable device output open circuit
Power supply
1
Injector supply voltage problem
4
For 6125HF070 only
628
240
ECU unswitched power missing
For 6068HF275 VP44 only
Battery voltage below the operating
For John DEERE Tiers III
voltage
Memory fault in EMS2
629
254
ECU status/controller error
18
2
RAM cell test failure
8
CPU watchdog reset test failure
11
Main and fuelling ASIC test fail
12
RAM address test failure
13
Watchdog trip failure
ECU to injection pump communication Possible
only
error
6068HF475 VP44
Data set memory EEPROM
19
630
253
632
636
with
Injection status
2
Fuel shutoff error
5
Fuel shutoff non-functional
Pump position sensor/Cam position
Pump position or CAM
sensor/Speed sensor CAM
position in function of the
Pump position sensor/cam position
type of injection
sensor input noise
Permanent loss of signal
High impedance of the position sensor or
circuit open
Sensor short to ground
Pump position sensor/cam position
sensor input missing
Not informed by VOLVO
Pump position sensor/cam position
sensor input pattern error
Crank position sensor/Speed sensor
flywheel
Crank position input noise
21
2
3
5
6
8
9
10
637
CIU module status
22
2
3
8
Permanent loss of signal
High impedance of the position sensor or
open circuit
Sensor short to ground
Crank position/Cam position out of
synchronisation
Crank position input missing
9
Not informed by VOLVO
10
Crank position sensor input pattern error
5
6
7
200/209
639
247
231
PID
PPID
FMI
2
Bus Off error
9
Passive bus error
11
Data registers read back failure
12
Loss of message error
13
Bus CAN error
Comment
Engine shutdown vehicle status
11
Engine shutdown vehicle request invalid
31
Engine shutdown vehicle request
Status of the Turbo with variable
geometry
Supply voltage of the Turbo actuator low
Error in communication between the ECU
and the TGV actuator
Error in position of the TGV
Temperature of the actuator moderately
high.
Fan supply
641
4
12
13
16
647
3
5
1
1
651
Injector outside specifications
1
Injector outside specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #1 circuit open
6
Cylinder #1 circuit shorted
Cylinder #1 balancing error/mechanical
failure
Cylinder #1 unknown error/mechanical
failure
Cylinder #2 injector status
11
2
Open circuit
0
7
2
Short circuit to earth
Cylinder #1 injector status
3
652
Description
Communication status
640
651
Perkins
SID
Volvo
CID
John Deere
SPN
652
0
Injector outside the specifications
1
Injector outside the specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #2 circuit open
6
Cylinder #2 circuit shorted
Cylinder #2 balancing error/mechanical
failure
Cylinder #2 unknown error/mechanical
failure
3
7
11
201/209
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
PID
653
3
3
653
PPID
FMI
0
Injector outside the specifications
1
Injector outside the specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #3 circuit open
6
Cylinder #3 circuit shorted
Cylinder #3 balancing error/mechanical
failure
Cylinder #3 unknown error/mechanical
failure
Cylinder #4 injector status
7
11
4
4
654
0
Injector outside the specifications
1
Injector outside the specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #4 circuit open
6
Cylinder #4 circuit shorted
Cylinder #4 balancing error/mechanical
failure
Cylinder #4 unknown error/mechanical
failure
Cylinder #5 injector status
3
7
11
655
5
5
Description
Comment
Cylinder #3 injector status
3
654
Perkins
SID
Volvo
CID
John Deere
SPN
655
0
Injector outside the specifications
1
Injector outside the specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #5 circuit open
6
Cylinder #5 circuit shorted
Cylinder #5 balancing error/mechanical
failure
Cylinder #5 unknown error/mechanical
failure
3
7
11
202/209
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
Recalibration of the injectors
required
PID
656
6
6
656
PPID
FMI
0
Injector outside the specifications
1
Injector outside the specifications
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #6 circuit open
6
Cylinder #6 circuit shorted
Cylinder #6 balancing error/mechanical
failure
Cylinder #6 unknown error/mechanical
failure
Glow plug relay status
7
11
39
677
678
39
3
Glow plug relay voltage high
5
Glow plug relay voltage low
3
3
Start relay control short circuit to high
4
Start relay control short circuit low
5
Start relay control open circuit
3
ACM 8 Volt DC supply open/short to B+
ACM 8 Volt DC supply open/short to
ground
Regulation sensor of the injection
pressure control
Secondary speed sensor
Secondary engine speed sensor data
intermittent
Secondary engine speed sensor loss of
signal
Loss of signal/sensor failure
Inlet
air
heater
signal/Preheat
detection
Inlet air heater signal high
5
Inlet air heater signal low
4
42
342
2
11
12
729
70
810
Vehicle speed
2
861
861
Calculated vehicle speed input noise
Not possible with Genset
application
Diagnostic output status
3
Diagnostic output open/short to B+
4
Diagnostic output short to ground
898
CAN throttle status
9
970
Recalibration of the injectors
required
Recalibration of the injectors
required
8 Volt power supply
3
723
Comment
Start relay status
41
679
Description
Cylinder #6 injector status
3
676
Perkins
SID
Volvo
CID
John Deere
SPN
6
2
31
971
Speed value invalid or missing
Auxiliary engine shutdown switch
status EMS
Auxiliary engine shutdown switch signal
Not used
invalid
Auxiliary engine shutdown switch active
External engine de rate switch status
31
External engine de rate switch active
203/209
Not used
PID
PPID
FMI
1069
Comment
2
Tire size error
9
Tire size invalid
31
Tire size error
5
6
Feed pump of the fuel circuit
High impedance at the terminals of the
pump or open circuit
Pump coil short to ground
12
Pump defective
1076
Not possible with Genset
application
Fuel Injection pump status
0
Pump control valve closure too long
Injection DE10
1
Pump control valve closure too short
Injection DE10
2
Pump detected defect
Injection VP44
3
Pump solenoid current high
Injection DE10
5
Pump solenoid circuit open
Injection DE10
6
Pump solenoid circuit severely shorted
Injection DE10
7
Pump control valve closure not detected
Injection DE10
10
Pump solenoid circuit moderately shorted Injection DE10
13
Pump current decay time invalid
1077
Injection DE10
Fuel injection pump controller status
7
Attempting to fuel without command
11
Pump supply voltage out of range
12
Pump self test error
19
Pump detected communication error
31
Pump initiated engine protection
1078
7
11
31
1079
232
1080
ECU/Pump timing status
ECU/Pump timing moderately out of
synchronisation
ECU/Pump timing speed out of
synchronisation
ECU/Pump timing extremely out of
synchronisation
Sensor supply voltage (+5 Volt)
Analog throttle reference
3
Sensor supply voltage high
4
Sensor supply voltage low
Sensor supply voltage (Oil
pressure)/+5V sensor supply 2
Sensor supply voltage high
211
3
4
1109
Sensor supply voltage low
Engine/ECU status
31
1110
Engine shutdown warning
Engine status
31
268
Engine shutdown
Check parameters
2
1136
Description
Tire size status
1075
1111
Perkins
SID
Volvo
CID
John Deere
SPN
55
Programmed parameter fault
ECU Temperature
0
ECU temperature extremely high
16
ECU temperature moderately high
204/209
> 5,5 Volt
< 4,44 Volt
pressure, Coolant
> 5,5 Volt
< 4,40 Volt
temp,
fuel
PID
PPID
FMI
1172
3
4
1180
1184
Input temperature of the TGV
compressor
Input voltage of the temperature sensor
Short to V+
high
Input voltage of the temperature sensor
Short to Vlow
Input temperature of the TGV turbine
Turbine temperature extremely high
Short to V+
Turbine temperature moderately high
Short to V-
Exhaust gas temperature sensor
Status of the pressure system of the
common rail
96
Pump control valve status
3
Pump control valve current high
5
Pump control valve error/mismatch
7
Fuel rail pressure control error
10
Pump control valve fuel flow not detected
1348
Pump control valve #2 status
5
10
1485
Comment
0
1347
1485
Description
16
173
1239
Perkins
SID
Volvo
CID
John Deere
SPN
5
ECU main relay of VOLVO
EMS/EDC
Pump power relay fault
ECU main relay short circuit
high
3
1568
Only for 6081HF070
Pump control valve #2 error/mismatch
Pump control valve #2 fuel flow not
detected
Pump power relay status
2
Pump control valve #1
status for 6081HF070
Torque curve selection
2
Torque curve selection invalid
4
Torque curve input voltage high
9
Torque curve selection missing
31
Fuel de rate
1569
Fuel supply status
1639
Fan speed
1
Fan speed zero or absent
2
Fan speed signal erratic
Fan speed more than 300 rpm above its
setpoint for at least 180s
Fan speed more than 300 rpm below its
setpoint for at least 180s
ECU status
16
18
2000
6
Vehicle ID missing
13
Security violation
0
Air temperature extremely high
3
Sensor input voltage high
Short to V+
Short to V-
2630
Air temperature at the air cooler outlet
4
Sensor input voltage low
15
Air temperature high
16
Air temperature moderately high
205/209
PID
PPID
FMI
2659
Description
Comment
Flow level of the EGR valve
2
Calculated EGR flow not valid
15
Calculated EGR flow rather high
17
Calculated EGR flow rather low
Air temperature at turbo compressor
outlet
Temperature at compressor outlet
moderately high
Statuses of the EGR valve
2790
16
2791
Perkins
SID
Volvo
CID
John Deere
SPN
19
2
Valve position signal not valid
3
Input voltage of the position sensor high
4
13
Input voltage of the position sensor low
Short to VInability of the EGR valve to reach the
expected position
The EGR valve is out of calibration
31
Error in position of the EGR valve
7
2795
520192
8
Position of TGV actuator
The actuator does not respond or is not
in the expected position
Common supply voltage of the
sensors, output #1
Supply voltage of the sensor too high
Supply voltage of the sensor shorted to
ground
Common supply voltage of the
sensors, output #2
Supply voltage of the sensor too high
Supply voltage of the sensor shorted to
ground
Common supply voltage of the
sensors, output #3
Supply voltage of the sensor too high
Supply voltage of the sensor shorted to
ground
Common supply voltage of the
sensors, output #4
Supply voltage of the sensor too high
Supply voltage of the sensor shorted to
ground
Common supply voltage of the
sensors, output #5
Supply voltage of the sensor too high
Supply voltage of the sensor shorted to
ground
Cooling status of the piston
520194
4
Status of the starting request input
520195
6
Stop request on CIU
7
3509
3
3510
3
3511
3
3512
3
3513
3
206/209
Short to V+
Exceeding +5 volts
Exceeding +5 volts
Exceeding +5 volts
Exceeding +5 volts
Exceeding +5 volts
SAE J1939-73 : March 2004
FMI and Description
FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what
would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world
condition (Region e of the signal range definition) Broadcast of data values is continued as normal. Broadcast of data values is
continued as normal.
FMI=1—DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what
would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world
condition
(Region
e
of
the
signal
range
definition).
Broadcast of data values is continued as normal.
FMI=2—DATA ERRATIC, INTERMITTENT OR INCORRECT
Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the real world
condition and must be caused by improper operation of the measuring device or its connection to the module. Broadcast of data
value is substituted with the “error indicator” value.
Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMIs 3, 4, 5
and 6. Data may also be considered incorrect if it is inconsistent with other information collected or known about the system.
FMI=3—VOLTAGE ABOVE NORMAL, OR SHORTED TO HIGH SOURCE
a. A voltage signal, data or otherwise, is above the predefined limits that bound the range (Region e of the signal range definition).
Broadcast of data value is substituted with the “error indicator” value.
b. Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands it to low.
Broadcast of data value is substituted with the “error indicator” value.
FMI=4—VOLTAGE BELOW NORMAL, OR SHORTED TO LOW SOURCE
a. A voltage signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal range definition).
Broadcast of data value is substituted with the “error indicator” value.
b. Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands it to high.
Broadcast of data value is substituted with the “error indicator” value.
FMI=5—CURRENT BELOW NORMAL OR OPEN CIRCUIT
a. A current signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal range definition).
Broadcast of data value is substituted with the “error indicator” value.
b. Any signal external to an electronic control module whose current remains off when the ECM commands it on. Broadcast of
data value is substituted with the “error indicator” value.
FMI=6—CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT
a. A current signal, data or otherwise, is above the predefined limits that bound the range. (Region e of the signal range definition).
Broadcast of data value is substituted with the “error indicator” value.
b. Any signal external to an electronic control module whose current remains on when the ECM commands it off. Broadcast of
data value is substituted with the “error indicator” value.
FMI=7—MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT
Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical
system that, with a reasonable confidence level, is not caused by an electronic or electrical system failure. This type of fault may or
may be directly associated with the value of general broadcast information.
FMI=8—ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD
To be considered in cases of FMI 4 and 5. Any frequency or PWM signal that is outside the predefined limits which bound the signal
range for frequency or duty cycle (outside Region b or the signal definition). Also if the signal is an ECM output, any signal whose
frequency or duty cycle is not consistent with the signal which is emitted. Broadcast of data value is substituted with the “error
indicator” value.
FMI=9—ABNORMAL UPDATE RATE
Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the
update rate expected or required by the ECM (outside Region c of the signal range definition). Also any error that causes the ECM
not to send information at the rate required by the system. This type of fault may or may be directly associated with the value of
general broadcast information.
FMI=10—ABNORMAL RATE OF CHANGE
Any data, exclusive of the abnormalities covered by FMI 2, that is considered valid but whose data is changing at a rate that is
outside the predefined limits that bound the rate of change for a properly functioning system (outside Region c of the signal range
definition). Broadcast of data values is continued as normal.
207/209
FMI=11—ROOT CAUSE NOT KNOWN
It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known. Broadcast
of data value is substituted with the “error indicator” value.
FMI=12—BAD INTELLIGENT DEVICE OR COMPONENT
Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used here to
mean the packaged unit that includes some microprocessor and its associated components and circuits. It can be assumed that the
communications subsystem is not the part that has failed, and the manufacturer has determined that there is no serviceable
component smaller than the ECU involved in the failure. Broadcast of data value is substituted with the “error indicator” value if
appropriate, as there may or may not be any broadcast involved. This error is to include all internal controller trouble codes that can
not be caused by connections or systems external to the controller.
FMI=13—OUT OF CALIBRATION
A failure that can be identified to be the result of not being properly calibrated. This may be the case for a subsystem which can
identify that the calibration attempting to be used by the controller is out of date. Or it may be the case that the mechanical
subsystem is determined to be out of calibration. This failure mode does not relate to the signal range definition as do many of the
FMIs.
FMI=14—SPECIAL INSTRUCTIONS
“Special Instructions” is the FMI to be used when the on-board system can isolate the failure to a small number of choices but not to
a single point of failure. When the FMI is used, there is clear necessity for the service technician to take some action to complete
the specific diagnosis, and the manufacturer has provided instructions for the completion of that diagnosis. There are two cases
where this will be used: 1. for emission-related diagnostics where the particular failure cannot be separated between a sensor out of
range and the case where the actual value is at the edge of a diagnostic region, and 2. for the older SPN 611 to 615 where the
problem is in determining which of two or more circuits (which may interact) is the one that needs repair.
SPNs 611 through 615 are defined as “System Diagnostic Codes” and are used to identify failures that cannot be tied to a specific
field replaceable component. Specific subsystem fault isolation is the goal of any diagnostic system, but for various reasons this
cannot always be accomplished. These SPNs allow the manufacturer some flexibility to communicate non-“specific component”
diagnostic information. Since SPNs 611-615 use the standard SPN/FMI format it allows the use of standard diagnostic tools,
electronic dashboards, satellite systems and other advanced devices that scan Parameter Groups containing the SPN/FMI formats.
Because manufacturer defined codes are not desirable in terms of standardization, the use of these codes should only occur when
diagnostic information cannot be communicated as a specific component and failure mode.
Possible reasons for using a System Diagnostic Code include:
1. Cost of specific component fault isolation is not justified, or
2. New concepts in Total Vehicle Diagnostics are being developed, or
3. New diagnostic strategies that are not component specific are being developed.
Due to the fact that SPNs 611-615 are manufacturer defined and are not component specific, FMIs 0-13 and 15-31 have little
meaning. Therefore, FMI 14, “Special Instructions”, is usually used. The goal is to refer the service personnel to the manufacturer's
troubleshooting manual for more information on the particular diagnostic code. This failure mode does not relate to the signal range
definition as do many of the FMIs. This type of fault may or may be directly associated with the value of general broadcast
information.
FMI=15—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - LEAST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what
would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world
condition (Region i of the signal range definition). Broadcast of data values is continued as normal.
FMI=16—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - MODERATELY SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what
would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real
world condition (Region k of the signal range definition). Broadcast of data values is continued as normal.
FMI=17—DATA VALID BUT BELOW NORMAL OPERATING RANGE - LEAST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what
would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world
condition (Region h of the signal range definition). Broadcast of data values is continued as normal.
FMI=18—DATA VALID BUT BELOW NORMAL OPERATING RANGE - MODERATELY SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what
would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real
world condition (Region j of the signal range definition). Broadcast of data values is continued as normal.
FMI=19—RECEIVED NETWORK DATA IN ERROR
Any failure that is detected when the data received via the network is found substituted with the “error indicator” value (i.e. FE16,
see J1939-71). This type of failure is associated with received network data. The component used to measure the real world signal
is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network. The FMI is
applicable to Region f and g of the signal range definition. This type of fault may or may be directly associated with the value of
general broadcast information.
208/209
FMI=20-30—RESERVED FOR SAE ASSIGNMENT
FMI=31—CONDITION EXISTS
Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the
reported SPN name spells out the component and a non-standard failure mode. This type of fault may or may be directly associated
with the value of general broadcast information. This FMI will mean “not available” when the associated SPN is also “not available”
as when the remainder of the packet is filled with binary ones after all data has been transmitted.
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Download Unitor HPC Extreme 520 Specifications